DESIGN AND ANALYSIS OF MULTI CUTTER HARVESTING

MACHINE

AUTHORS

MELAKU WOLDE…………....RAMIT/893/10

MELKAMU WORKU……….…RAMIT/

NIGUSE BELETE…………...…RAMIT/1082/10

SEBLEWORK AZMERAW…...RAMIT/1190/10

ADVISOR;DR.SELOMON

IN PARTIAL FULFILLMENT OF BACHELOR OF SCIENCE DEGREE WITH

MECHANICAL ENGINEERING

ARBA MINCH UNIVERSITY

ARBA MINCH INSTITUTE OF TECHNOLOGY (AMIT)

FACULTY OF MECHANICAL & PRODUCTION ENGINEERING

CERTIFICATION
DECLARATION
ACKNOWLEDGEMENT
ABSTRACT
CHAPTER ONE

INTRODUCTION

1.1 BACKGROUND OF MULTI CUTTER MACHINE

There are various designs of tools and equipment used for harvesting the crops, sickles, hand
tools and reapers for grain cross and diggers for tuber crops, operated with different power
sources are used. Combine harvester, both tractor mounted and self-propelled, are being very
widely used for different grain crops. Crops are harvested after normal maturity with the
objective to force out grain strains, tubers etc. without much loss. It involves cutting digging
picking, gathering, curing transport and stoking of the crops. In case of serials like wheat and
barley the pants are straight and smooth and cars containing grains are the top whereas most of
oil seed and pulse crops have branches, which create problems in harvesting by manual or
mechanical means. Seeds come in an immerse variety of shops and sizes .small grains include
wheat and rice or well small and slippery oil seeds such as flat and canola. Large seeds include
grain corn with seed on earth’s soy beans and other beans in rods Plant height varies from
ground hugging gear to elevated ears on tall corn stalks, such wide verities create unique
demands for harvesting machinery .all this crops from all seeds, gross clover seeds through to
large beans ‘grains ‘will be used here to include all types of seeds specially wheat and barley.
Harvesting is the operation of cutting, picking, plucking and digging or a combination of this
expression for removing the crop from under the ground or above the ground, or removing the
use full part of fruits from plants.

Harvesting action done by four ways. These are; Sickling action done with a sharp tool,
Tearing action with a rough serrated edge, High velocity single element input with sharp or
dull edge, Two elements scissor type action.

Harvesting can be done by; manually operated tool, Animal drawn machine, mechanically
operated machine. The harvesting of crops is traditionally done by manually methods.
Manually harvesting involves slicing and tearing action, harvesting of major cereals, pulse and
oil seeds crops are done by using sickle whereas tuber crops are harvested by country plough
or Spode .All this traditional methods involved dapperly and consume long time. In modern
agricultural harvesting is done with mechanical harvesting machines. Mowers, horizontal
rotary mower, reciprocating mower, cylinder mower, reaper, reaper binder, swatch, windrow
and sickle are some of modern harvesting machines. Timeliness of harvesting is the prime
importance during harvesting season, often rains and storm occur causing considerable
damage to standing crops harvest facilitates, extra days for land operations and earlier planting
of the next crop. The use of machines which help to harvest at proper stage of crop maturing
and reduce dragger and operation time .considering these improved harvesting tools,
equipment and combines are being accepted by the farmers. Until the 19 th century most grain
was harvested by cutting with a sickle, then manually flailed or beaten to break the bond of the
grain with the stalk, then win-knower to separate the grain from material other than grain.
During the 19th century mechanical reapers and binders were developed to cut and windrow
grain for field drying . In 1831, Cyrus H. McCormick developed the first commercially
successful reaper, a horse-drawn machine that harvested wheat. A cross between a
wheelbarrow and a chariot, the reaper was a horse-drawn machine that harvested wheat and
was capable of cutting six acres of oats in one afternoon, the equivalent of 12 people working
with scythes. around the start of 20th century animal drawn machines(combines) were
developed that integrated cutting, threshing and separating wheat and small grain. The
necessities of world war 2nd have tended the adoption of self-propelled combines. The majority
of today’s combines are rotary combines offering multi-crop threshing and rotary separation.
Optional equipment includes GPS, data collection, luxury panoramic view cabs, touchscreen
monitors, and more. The newest models are able to harvest almost 100 tons of small grains per
hour. These combines can range in price from $400K to $700K. With the additional cost of
headers, platforms and attachments, costs can rise to a million dollars.

The USDA reported in the 2017 survey of equipment on farms that there are currently 323,347
combines on farms in the US. This number is a testament to this amazing machine’s
utility.The price of new combines fluctuates year to year.
 Fig 1.1: Harvesting by combiner and animal pushed reaper

1.2 STATEMENT OF THE PROBLEM

Agricultural activities and production entirely depend on agricultural tools and equipment,
harvesting machines play a great role for mechanized agriculture. In our country most farmers
use different types of harvesting tools and equipment that are manually operated like sickle
that operated by human hand work. This kind of manual harvesting method is not effective for
modernized agriculture even for our country, because manual harvesting method is less
productive and it takes much time and energy.

In modern agriculture harvesting machines such as combine or mower that is driven by

tractors has been used, but for our country this machine is not easily affordable by the farmers
because of our economic level, and it is expensive to be used the whole farmers. Therefore, we
start to design and develop a manually operated multi cutter by using of some kind of
mechanisms such as cam and follower mechanism and a belt drive that gets driving power
from the wheels and it can be operated by one person. In addition to this it can harvest much
greater than that of manual harvesting by ordinary sickle to harvest by increasing the number
of cutters, which can minimizes labor, time and cost.

1.3 OBJECTIVE OF THE PROJECT

1.3.1 General objective

The main objective of this project is to design and analysis a push type cutter bar mower or
manually operated multi cutter harvesting machine which used for grass cutting in order to
overcome the above statement of the problem.
1.3.2 Specific objective

 To review the background of different types of harvesting multi cutter machines.

 To select appropriate materials for each parts of the machine.
 To analysis and design each component of multi-cutter harvesting machine.
 To draw 3D assembling of the machines using solid work software.
 To identify the mechanism of the machine (belt drive and cam mechanism).
 To identify functions of each components of the machine.

Finally if possible to design the manufacturing process of the parts and to estimate the cost
analysis.

1.4 SIGNIFICANCE OF THE STUDY

 To minimize the problem of farmers by designing and if possible by

manufacturing the machine.
 To modernize the agricultural sectors.
 To increases a chance for future investigation and modification for the
student’s.
 To help the farmers in order to improve the way of their harvesting
mechanism.
 The machine is not only require literate farmers to use it for cutting the
crops because it operates manually easily.
 Since cost of the machine is cheaper than motorized machines the
farmers can use it, so it has an advantage especially in our country.

1.5 SCOPE AND LIMITATION OF THE PROJECT

1.5.1 Scope of the project

The designed project used to harvest grass for the following operating conditions is
functional.

 Dry and level farm or ground.

 The machine is designed to operate by single person by pushing it.
1.5.2 Limitation of the project
The machine may not be functional for sloppy and wet areas because both factors play a great
role in increasing frictional force therefore more force is required to push the machine. In
rainy seasons the farm become wet and muddy, hence the wheels are hard to role on the
ground and cutting speed will be decreased. For moisture content greater than 45 the
shearing strength of the wheat stem become higher then, the efficiency of the cutter will be
decreased.

CHAPTER TWO

LITERATURE REVIEW
Feature of sickle
Sickle is one of the most common hand tools used for harvesting of the crops, grass and
cutting of other vegetative materials. The cutting edge may be plain or serrated depending up
on the design. The blade is fabricated from medium carbon or high carbon steel and hardened
to resist wear. Manganese steel, tool steel and hardened and alloy steel can also be used to
produce better quality sickles which have more life fabricated from the plain carbon.

The blade has a knife section and the thickness reduces towards the cutting edge. Tang of the
blade is inserted into the wooden handle. For joining the blade to the handle .the wooden
handle is either straight or bent at the end. for cutting the part of the plant to be cut is held one
hand and sickle operated with other hand .Cutting is achieved by imparting translator and
rotary moment to the blade around the point of cut .this action leads to applying frictional and
shearing force components required to achieve cutting.
For this reasons, a push type cutter bar mower was selected for exploring its adaptability in
solving farmers’ problems in terms of cost and versatility on various terrains of small-scale
enterprises and house hold application.

Fig 2.1: harvesting by ordinary sickle

Laukik P. Raut with its four students

They developed a compact harvesting cutter machine which is powered by the 2.2Kwatt, 3000
rpm diesel engine. With the help of V-belt, drive power is transmitted to gearbox. As the
required rpm at cutter is as less as 200 rpm, a spur gearbox and a bevel gearbox is used. Here
bevel gear is used to change the direction of drive in the gear system by 90˚. One end of this
output shaft is connected to slider crank mechanism which converts rotary motion of shaft into
reciprocating motion of cutter blade. Reciprocating cutter blade slides over fixed blade and
creates scissoring action responsible for cutting the crops. Collecting mechanism consist of
flat belt with collecting plates bolted on it. Collecting belt simply carry cut crops sideways.

Fig. 2.2: CAD model of Harvester

Design of grass cutter
In this project the idea is to make the mechanization of small scale grass cutting machine. The
machine focuses to combination of cutting and collecting the grass for small scale farmers.
Different parts of a machine will be mounted on strong chassis. The wheel will be attached to
this chassis. The petrol engine is mounted on the chassis which provides the power to the
wheels to move by chain drive and gear.
Although corn cobs have several uses, the lack of economical corn cob harvest equipment has
limited cobs to niche markets and impeded the adoption of new corn cob products, such as a
bio renewable fuel source regardless of the end lives, corn cobs provide ingredient
environment friendly products but first they have to be collected.

Classification of previous corn cob recovery systems in the literature reviews uses the
following three factors.

 Separation method
 Separation location
 Storage location

The corn cobs can be separated from the buck and lives by mechanical method, pneumatics
methods, or a combination of these methods, furthermore, separation can take place either on
the combine or through the use of at owed wagon with separation capabilities. if separation
occurs away from the combine, then storage also occurs away from the combine on the other
hand combine with method of separation have been developed with and without on board
storage.

The following literature review compares and discusses prior method of harvesting corn cobs.

Corn cob collection

Prior to the modern combine, corn was picked on the ear and shelled later (stone, 1905, snow,
1961) therefore, all of the cobs in the field where collected but the grain still had to be
threshed, and harvest was a labor intensive job. As harvesting grain become increasingly
mechanized, the cobs where left on the field. Barglet at (1982) developed one of the first
systems to collect cobs, based on pneumatic separation and a modified straw chopper to
chopper to accelerate MOG through a spout. Initially, this was a purely ballistic separation
method on assuming that due to different properties, cobs would exit the spout and land in a
trained wagon while the husks would fall between the combine and the wagon.

However, results were not as successful as expected and a fan was mounted between the
chopper and the spot the fan directly air at an angle of 110 degrees from material flow to force
lighter husk and leaf material back on to the ground while cobs kept travelling through the
spout with this design, 78% of the cobs were collected at a cob purity of 89%.

Furthermore, of the husk collect for the cobs, 40%were attached to the cobs .this cobs husk
fraction accounted for 34% of totally material weight, with composing 5% of the cobs husk
fraction .This study also reported a decrease in bulk density from 192 to 100kg/m 3 (12 to 6.25
lb. /ft3) as the cob purity decreased from 100% to 85%.

The proto type harvester used a bounce plate at a forty-five degree angle below the straw
walker and deflectors after the chamfer .the conveyor contained to move husk and stalks away
while allowing cobs to bounce and failed in to the collection container.

Additionally air from chamfer also helped improve separation after the straw walker. with the
belt conveyor this system achieved collection efficiencies of 88% with purity of 94% system
provides two methods of separation depending on customer input for both conventional and
rotary combines .For convectional combines, the straw walker can be modified to larger
opening to allow corn cobs to pass through the to the sieve. For a rotary combine, the standard
grain sieve can be used or a second sieve can be installed.

Flambé (1990) developed a cob separation system utilizing a towed cart this cart, commonly
referred to as the ―cob caddy ―collects the discharge from the combine on conveyor. The
conveyor moves the cobs, stalks, and husk upward and towards a stream of air. The lighter
husk stalk material is caused to exit the material stream and is discharged back to the
ground .cobs continuing another conveyor which moves them into collection bin. While not
capable of unloading on the go, it does remove material conveyance issues through use of a
side dump unloading technique.

Victor and Vern’s, (2003) designed and developed a power operated rotary weedier for wet
land paddy. The complex nature of the machine makes its maintenance and operation difficult
for the peasant farmers. Generally, in areas like ours, the conventional methods of grass
cutting involved the use of cutlasses whichever met the maximum satisfaction. More so, it is
strenuous, time and labor intensive.

Fig.2.3;rotary weeder

Therefore, the objectives of this study were to design a simple, strong and inexpensive grain
harvesting machine operated by a single person for flat and leveled topographies for several
kinds and characteristics of crops, grown in small-scale enterprises in Ethiopia, reduce
dependency of grain (wheat, barely) harvesting on tractor-mounted mowers, and reduce
human fatigue, compared with scythes or sickles. Especially our project is considers
addressing low income farmers and farmers which have not enough knowledge to use the
technology.
 CHAPTER THREE

MATERIALS AND METHODOLOGY

3.1 MATERIAL SELECTION FOR EACH PARTS

The selection of a proper material, for engineering purposes, is one of the most difficult
problem for the designer. The best material is one which serve the desired objective at the
minimum cost. The following factors should be considered while selecting the material:

 Availability of the materials,

 Suitability of the materials for the work-ing conditions in service, and
 The cost of the materials.
The important properties, which determine the utility of the material are physical, chemical
and mechanical properties. The physical properties of the metals include luster, color, size and
shape, density, electric and thermal conductivity, and melting point. The mechanical
properties of the metals are those which are associated with the ability of the material to resist
mechanical forces and load. These mechanical properties of the metal include strength,
stiffness, elasticity, plasticity, ductility, brittleness, malleability, toughness, resilience, creep
and hardness. Now we will select good materials for each parts of the machine depending on
the standards and by considering other factors.

3.1.1 Handle

A handle is a part of, or attachment to the main frame that allows the machine to
be grasped and manipulated by hand. It is a push type handle that can able to resist twisting
moment when the force is applied on it.

Indian standard Composition in percentages Uses as per IS : 1871 (Part II)–

Designation Carbon(C) Manganese(Mn) 1987
(Reaffirmed 1993)
30C8 0.25-0.35 0.60-0.90 It is used for making cold formed
parts such as shift and brake
levers. After suitable case
hardening or hardening and
tempering, this steel is used for
making sprockets, tie rods, shaft
fork and rear hub, 2 and 3 wheeler
scooter parts such as sprocket,
lever, and hubs for forks, cams,
 rocket arms and bushes. Tubes for
aircraft, automobile, bicycle and
furniture are also made of this
steel.
35C4 0.30-0.40 0.30-0.60
It is used for low stressed parts,
automobile tubes and fasteners.
35C8 0.30-0.40 0.60-0.90
It is used for low stressed parts in
machine structures, cycle and
motor cycle tubes, fish plates for
rails and fasteners.
40C8 0.35-0.45 0.60-0.90
It is used for crankshafts, shafts,
spindles, push rods, automobile
axle beams, connecting rods,
studs, bolts, lightly stressed gears,
chain parts, umbrella ribs,
45C8 0.40-0.50 0.60-0.90 washers, etc.

It is used for spindles of machine

tools, bigger gears, bolts, lead
screws, feed rods, shafts and
rocks.

Therefore from the above table we have selected the material of carbon steel 45C8 with an
ultimate tensile strength of 610-700MPa, modulus of elasticity, E=210Gpa and yield strength
of 350MPa.the selected material has a diameter of 30mm and length of 1000mm in order to
satisfy the required objective.

3.1.2 Main Frame

The frame is an important part of the machine. All the remaining components of the machine
are mounted on it. It is a rigid structure that forms a skeleton to hold all the components
together.it is an assembly of rigid members designed to do mechanical work by transmitting a
given set of input loading forces into another set of output forces. Each frame jointed from the
base and the shafts that carry the wheel, belt, pulley, cam and the cutter bar to be inserted on it
by using bearing. The bearing house bolted with the frame and holds the shaft carrying
different components and the cutter bar
 Different types of frame structures can be constructed from various materials such as
reinforced concrete, steel, and wood. A Frame structure is a structure having the combination
of beam, column and slab to resist the lateral and gravity loads. These structures are usually
used to overcome the large moments developing due to the applied loading. Therefore the
frame material is made from mild steel of 45C8 for stability and rigidity which have modulus
of elasticity, E=0.21 × 106 N/mm2 and yield strength, SY=350Mpa with the ultimate tensile
strength ranges from 610-700Mpa.

A buckling response leads to instability and collapse of the members. It is the ability of
a structure to support a given load without sudden change in configuration. For the
failure to occur yielding or crushing without buckling, at stress above proportional
limit.

3.1.3 Shaft
A shaft is a rotating machine element which is used to transmit power from one parts of
body to another part. The power is transmitted to the shaft by some tangential force and
the resultant torque (twisting moment) set up within the shaft permits the power to be
transferred to various members such as pulleys, gears are mounted on it. These
members along with the force exerted up on them cause, the bending. In the other
words ,we may say that a shaft is used for the transmission of torque and bending
moment the various members are mounted on the shaft by means of keys or spines.

NOTES: from the subject view there are two types of shafts. These are;

1. Transmission shafts. These shafts transmit power between the source and the
machines absorbing power. The counter shafts, line shafts, overhead shafts and all
factory shafts are transmission shafts. Since these shafts carry machine parts such as
pulleys, gears etc., therefore they are subjected to bending in addition to twisting.

2. Machine shafts. These shafts form an integral part of the machine itself. The crank
shaft is an example of machine shaft.

From the above descriptions, our shaft is transmission shaft which carry the pulleys and
can transmit power from the wheel to the cutter using belt drives mechanism.

Material for shafts: The materials used for shafts should have the following properties:
  It should have high strength
 Have good Machinability
 It should have good notch sensitivity factor
 Have good heat treatment properties.
 It should have high wear resistance property.

The material used for ordinary shaft is carbon steel of grades 40C8, 45C8 , 50C12. The
mechanical properties of these grades of carbon steel are given in the table below.

Indian standard designation Ultimate tensile Yield strength (MPa)

strength(Mpa)
40c8 560-670 320
45c8 610-700 350
50c4 640-760 370
50c12 700min 370
Table. Mechanical properties of steels used for shafts.

So among these materials we have selected carbon steel of grade 40c8 depending on the
properties of the materials that safe for the goals. The standard sizes of transmission shafts are:
25 mm to 60 mm with 5 mm steps; 60 mm to 110 mm with 10 mm steps; 110 mm to 140 mm
with 15 mm steps; and 140 mm to 500 mm with 20 mm steps. From these standards we have
selected a diameter ranges from 25mm to 60mm.

3.1.4 Belt Drive

A belt is a loop of flexible material used to link two or more rotating shafts
mechanically, most often parallel. Belts may be used as a source of motion, to transmit
power efficiently, or to track relative movement. Belts are looped over pulleys and may
have a twist between the pulleys, and the shafts need not be parallel. In a two-pulley
system, the belt can either drive the pulleys normally in one direction (the same if on
parallel shafts), or the belt may be crossed, so that the direction of the driven shaft is
reversed (the opposite direction to the driver if on parallel shafts).

The amount of power transmitted depends up on 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 condition under which the belt is used

Selection of a belt drive: The various important factors up on which the selection of a belt
drive depends on the Speed of driving and driven shaft and also the following:

1. Power to be transmitted
2. Speed reduction ratio
3. Center distance between the shaft
4. Positive drive requirements
5. Shafts layout
6. Space available and
7. Service conditions

Types of belts: There are many types of belts used these days yet the following are
important from the subject point of view.

1. Flat belt. The 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 metres apart.
2. V- belt. The 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.
3. Circular belt or rope. The 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 metres apart.
As we have seen from the above description for transmission of power in small
distance using V-belt is necessary. Therefore we need to select a v-belt because of
the minimum center distance between the pulleys and in order to protect slippage of
belt. 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:

 Leather belts
 Cotton or fabric belts
  Rubber belts
 Balata belts
The V-belts are made of fabric and cords moulded in rubber and covered with
fabric and rubber .These belts are moulded to a trapezoidal shape and are
made endless. These are particularly suitable for short drives. The included
angle for the V-belt is usually from 30° to 40°. The cotton or fabric belts are
cheaper and suitable in warm climates, in damp atmospheres and in exposed
positions. Since the cotton belts require little attention, therefore these belts
are mostly used in farm machinery, belt conveyor etc.

Material of belt Mass density in

kg / m3

Leather 1000
Convass 1220
Rubber 1140
Balata 1110
Single woven belt 1170
Double woven belt 1250

Table .density of belt materials

3.1.5 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 diameter 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. The pulleys are generally made of cast iron, because of their low cost.
Therefore we also selected cast iron pulley because of the above factors. The dimensions for
the standard V-grooved pulley according to IS: 2494 – 1974, are shown in Table below.
Table. Dimensions of standard V-belts according to IS: 2494 – 1974.

Type of belt Power ranges Minimum Top width (b) Thickness (t) Weight per
in kW pitch Mm mm meter length
diameter of in newton
pulley (D)
mm
A 0.7 – 3.5 75 13 8 1.06

B 2 – 15 125 17 11 1.89

C 7.5 – 75 200 22 14 3.43

D 20 – 150 355 32 19 5.96

E 30 – 350 500 38 23 -

Table . Dimensions of standard V-grooved pulleys according to IS : 2494–1974. (All

dimensions in mm)
Table. Standard pitch lengths of V-belts according to IS: 2494-1974.

3.1.6 Caster Wheel

Casters are useful for many different tasks, but no one caster is the best choice for all
applications. Many things come into consideration such as the floor type,

environmental conditions, load capacities, and even mounting preference. Wheel must
be light in weight if it is to maintain grip when the harvesting machine is traveling over
a hump surface at high speed. Therefore we need to use tired wheel in order to decrease
friction between the wheel and the ground and to have light weight. We have seen that
the maintenance of bolt in the wheel. There are three types of bolts used for the wheels:

1. Pressed steel disc

2. Wire bolt and
3. Light alloy bolt

1. Pressed steel disc: It is a rolled steel rim welded to a center disc.

2. Wire bolt: A steel rim attached to the hoop by wire spokes to give light weight
supports wheel.

3 .light alloy: It is light weight comparatively high cost of wheel.

The selected material for the wheel is cast iron in order to perform at high speed, it can also
carry high load and the friction is less, it can resist the wear generated due to increase in
friction and also resistant to fatigue. They’re also cheaper than steel and were once easier to
cast.

Fig 3.1: Wheel with its terminology

The wheel has four number of arm and Let us assume the outer diameter as 400mm which is
good enough for the machine to move freely on the ground.

3.1.6 Bearing

Bearing is a device that is used to enable rotational or linear movement, while reducing
friction and handling stress. Resembling wheels, bearings literally enable devices to roll,
which reduces the friction between the surface of the bearing and the surface it’s rolling over.
It’s significantly easier to move, both in a rotary or linear fashion, when friction is reduced,
this also enhances speed and efficiency. There are numerous different kinds of bearings that
are designed to handle radial load, thrust load, or some combination of the two. Depending
upon the nature of contact the bearing can be classified as:

1. Sliding contact bearings; in sliding contact bearings the sliding takes place along the
surfaces of contact between the moving element and the fixed element. And

2. Rolling contact bearings; in rolling contact bearings the steel balls or rollers, are interposed
between the moving and fixed elements. The balls offer rolling friction at two points for each
ball or roller. Rolling contact bearings has some advantages over sliding contact bearings.
Those are;

 Low starting and running friction except at very high speeds.

 . Ability to withstand momentary shock loads.
 Accuracy of shaft alignment.
 Low cost of maintenance, as no lubrication is required while in service

Since the rolling elements are subjected to high local stresses of varying magnitude with each
revolution of the bearing, therefore the material of the rolling element (i.e. steel) should be of
high quality. The balls are generally made of high carbon chromium steel.Chrome steel is used
to make ball bearings, rollers and bearing rings. Bearing steel has high and uniform hardness
and wear resistance, as well as high elastic limitAlso it have excellent surface quality. And
they offer superior wear resistance, high hardness and high load bearing capacity as a result of
through-hardening. Therefore we have selected a material of hardened steel.

Table: principal dimension for radial ball bearing

Bearing No. Bore (mm) Outside diameter Width (mm)

200 10 30 9
300 35 11
201 12 32 10
301 37 12
202 15 35 11
302 42 13
203 17 40 12
303 47 14
403 63 17
204 20 47 14
304 54 14
404 72 19
205 25 52 15
305 62 17
405 80 21
206 30 62 16
306 72 19
 406 90 23
Therefore from the above table we have selected Bearing number=206, Bore= 30mm, outside
diameter=62mm, Width= 16mm.

Fig: 3.2 roller ball bearing

3.1.7 Key

A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley to
connect these together in order to prevent relative motion between them. It is always inserted
parallel to the axis of the shaft. Keys are used as temporary fastenings and are subjected to
considerable crushing and shearing stresses. There are different types of key. Those are; Sunk
keys, Saddle keys, Tangent keys, Round keys, and Splines. The main functions of key are;

 To transmit torque from shaft to hub of the mating element such as the pulley, gear,
etc.
 To prevent relative motion between the shaft & mating machine element.

Shaft keys (and machine keys) can be made from a variety of materials. Generally, shaft keys
are built from carbon steel or stainless steel but can be made from brass, copper, aluminum,
monel, and even nylon, all with material grades. AISI 316 stainless is also prepared for marine
applications. Therefore the selected material is carbon steel rectangular sunk key. Because
Carbon steel is used more broadly than any other material. Carbon steel provides very good
strength through heat treatment.
 Fig : 3.3 geometry of rectangular sunk key

3.1.8 Cylindrical cam

This is a profile made on the surface of the cylinder that is used for the reciprocation of the
cutter horizontally. A slot is cut into a flat plate or normal to the axis of a cylinder. Slotted
holes are widely used in most sorts of mechanical design. Apply mainly in precisely fine-
tuning for uncontrollable dimensions beforehand, alignment accuracy, fixation in certain
direction meanwhile keeping slipping free in other directions, and so on.

When selecting a material for design of cylindrical cam, as the cam designer we will
first determine the requirements for the cams being considered. The design
requirements for a cam in a given application will depend on such things as accuracy,
load, and speed, material, and noise limitations. The more stringent these requirements
are, the more costly the cam will become.
Some of the considerations in the choice of a material include allowable hertzian stress,
wear resistance, impact strength, water and corrosion resistance, manufacturing cost,
size,
weight, reliability, and lubrication requirements. Steel, under proper heat treatment,
meets
most of these qualifications for roller followers while cast iron is excellent for
sliding followers.
Depending on the above requirements we have selected cast iron materials for our cam
mechanisms.in addition to the above cast iron has some good propertis.these are;
 its low cost,
 good casting characteristics,
  high compressive strength,
 wear resistance and
 Excellent machinability.
The compressive strength of cast iron is much greater than the tensile strength.
Following are the values of ultimate strength of cast iron :
Tensile strength = 100 to 200 MPa
Compressive strength = 400 to 1000 MPa
Shear strength = 120 MPa

Fig : 3.4 cam profile on cylinder

The diameter of the cylinder is twice of that of the shaft in which the cylinder is
inserted on it and the length of the cylinder is equal to the width of two cutters and
letting some clearance in order to keep self-guidance of the bar inserted to the slot.

The slot profile is made on the half thickness of the surface of the cylinder to maintain the
strength of the cylinder during the reciprocation period. The bar attached to the cutter bar is
inserted in this profile in order to give the cutters a reciprocating motion

3.1.9 Cutter

The cutting unit, which was attached to the main frame, has two-knife bar sections; the upper
one reciprocates over the stationary bottom one. The cutter is made of steel Indian standard
designation of 70C6 with an oblique angle of 30º and smooth knife edge to decrease the
shearing strength of wheat stalk or to harvest at minimum force. Standard sizes of the cutter
found to be

 Length of cutter =67mm

 Width of cutter =50.8mm
 Blade thickness=1.5-4mm
 Hardness of the cutting edge=37-46HRC,

A single cutter from the parameters gives the machine width. From the above standard
dimensions of sickle given from the parameters, we select for our design minimum sickle
width of 50.8mm.

The width of the cutter frame is sum of the width of all cutters. The aim of this project is to
design a grain harvesting machine that is operated by human force by getting a driving
mechanism from the rotation of the wheels. Therefore, it can be operated with up to 19cutters.

Thus, the width of the cutter frame is the sum of the width of each cutter.

w cf =n∗w c=19*50.8=965.2mm

Where, w cf =cutter frame width

ԝc =width of sickle

n=number of sickle

By letting some clearance for the cutter bar to reciprocate freely the width of the machine
become w=1000mm

The overall height of the machine is assumed up to the handle of the machine. So, the height
can be assumed to be 1m from the ground

This assumption is taken by considering the operational structure of the machine. A person
can operate by this machine when he/she is standing on; the handle is assumed to be parallel
to the mid- way of human height.

This overall height is including the height of the handle and it can be operated up to 100cm
above the ground .therefore the height of the machine without the handle is 100cm=1m.

The overall length the machine can be estimated by considering the following conditions.

 The distance between the front and rear wheel

 The storage area produced to store the harvested crop

Therefore, the assumed overall length of the machine is to be up to 150cmi.e. Overall

length=150cm .
 3.2 METHODOLOGY

Methodology is a set of methods and principles that used for designing and analyzing our
project. It is important because it ensures proper expectations are set around what can be
delivered. It also helps to have better control of the variables which contribute to the well-
being of the project process. For these reasons we tried to follow some procedures which will
enable the whole project to be efficient and effective. In this project the idea is to make the
mechanization of small scale grain harvesting machine. Before starting the project some
information and data are collected from different data sources that are very helpful for the
continuity of the project. Some of the data sources that we gathered information are
referencing books, internet, different designed projects that are related to our project. For
designing this project in addition to data sources, many materials are used that are essential for
the completion of the project such as computer, papers, pen and drawing materials.

By using the above data sources the materials that are used for the different parts of the
machine with their mechanical properties and operational characteristics will be selected.
These parts will be designed based on different design analyses by considering their shearing,
bending, crushing and torsional stresses from the available data.

Generally when we put the methods in a block diagram it looks like this;
Start

↓
Studying the present
mechanisms

↓
identifying the potential
problem

↓
 Problem definition

↓
Literature review

↓
Material selection

↓
Design of manual operate
multti cutter

↓
Analysis of manual operate
multti cutter

↓
Drawing each part of the
machine using solid work

↓
Preparing 3D Assembling
drawing
 CHAPTER FOUR

DETAIL DESIGN AND DISCUSSIONS

4.1 GEOMETRIC ANALYSIS

In this section it will be discussed about the general mechanisms used for the machine, the
dimensional analysis of the machine. In this design we used a quick return mechanism for the
cutting operation, i.e.it can be operated by using intermittent action of the arm of the
mechanism or forward and back ward motion of the quick return mechanism by getting a
driving force from the rotation of the wheels attached to the link of the mechanism by using a
belt drive.

The dimensional analysis of the machine in this project will be discussed below.

We used the given parameters of standards to find out the main principal dimensions of the
machine. In this design the basic standard parameters gives the machines dimensions. The
width, length, and height of the machine that will be designed are selected from the
parameters.

4.2 FORCE AND STRENGTH ANALYSIS

In this part of design we will do the analysis of the forces and stresses actions on the machine.
The total weight of the machine will be also known from summation of force consideration.

4.2.1 Design for Power Requirement

This is described as how the machine of the power requires to driven by human power .from
the existing data’s the average output power of human is 300 watts. (Suggestion)

By considering the variation of power according to different peoples, the average driving
power of healthy person in temperate climate consumes 300watts.While in tropical climates as
a result of heat stress the rate is consumed to 250watts.

The fact that many primary agricultural production operations demand higher rates of energy
rates energy than the maximum sustainable rate energy consumption by humans necessitates
rest periods in manual work. The rest period required can be estimated by using the formula.
T r=60 ¿ ) , Where,T r=¿ = required period in min/h of work. P = actual rate of energy
consumption in watts using the formula it follows that the manual riding operation which
demands 400—1000w requires rest periods of between 22.5 and 45 minutes per hour of
work .note that at 1000 rate of energy consumption the farmer can work only for 15 minutes
and must rest for 45 minutes per hour of work.

From 0.3kw only 25% of the energy is consumed and the physical power output is
approximately 0.075kw sustained for an 8 -10 hour work day.

But normally the average human power ranges from 60 to 120watt, therefore the selected
human power delivered by humans for manual work is 75watt from the above data, and the
average force applied will be 150-250N. Let us take the force applied to drive the machine as
240N.

Therefore p=75w and F=240N

Let us calculate the torque, speed and time required to harvest one hectare farm by using the
available data from the equation below.

T=F×R

Where, T=torque produced on the wheel

F=force required to push the machine

R=radius of the wheel

Now let us select the diameter of the rear wheel of the machine, and then let us assume the
diameter of the wheel as

D=350mm, R=d/2=350/2=175mm

=0.175m

Therefore, T=F*R=240N*0.175m=42Nm

Where F=240N and R=0.175m

To calculate the speed of the person while pushing the machine, first let us get the revolution
or rpm of the wheel.
 T= 60 P
It can be calculated from the equation, 2 πN

Rearranging the equation gives N=60P/2πT=60*75/2π*42

=17.05rpm

To get the linear velocity of the person while pushing the machine (v), firstly the angular
velocity ( must be calculated. It can be found by applying the equation

2 π × N 2 π ×17.05
ω¿ = =1.8rad/sec
60 60

Then the linear velocity of the person will become V=ω*R=1.8rad/sec*0.175

=0.35m/sec

The time required to harvest one hectare farm by the machine will be calculated by taking a
distance traveled by the person while pushing of 1m and it can be found as follows.

S=v/t,t=s/v=1m/0.35m/sec

=2.9sec say 3sec Where, s=the distance traveled

V=the speed of the person

t=time required to harvest

The total time required to harvest one hectare farm will be the sum of all distance .i.e. the total

area to be harvested is 1 hectare=100m*100m

Therefore the total time will become t=3sec*10000=30000sec

=500min=8.33hr

As we gathered information from different sources to compare the time required for manual
harvesting and the designed machine, it needs 8-10 man working for 8-10 hours to harvest
one hectare farm by manual harvesting.

For manual harvesting a farmer can work for 15minutes and must rest for 45minutes in one
hour, therefore the total time consumed for 1 farmer in 8 hours to harvest 1hectare farm
become,
 15 min
t= *8hr=120min
hr

The total time required for 8 farmers will be

t=8*120min=960min=16hr

Therefore it can be conclude that the designed machine is more effective than manual
harvesting by comparing the time consumption.

4.2.2 Total Mass of Machine

The total mass of the machine can be found by two ways, the first one is based on calculation
of summation of forces at equilibrium position and secondly finding the mass of each parts
and summing up them to get the total mass of the machine.

The total mass of the machine will be calculated from the force requirement as follows, the
free body diagram of the machine including all the forces acting on it is shown below.

θ Fx

Fx

Fr

Fig: representation of forces acting on the machine

Where =motive or pushing force

F γ =µN= resisting or frictional force

θ =Angle of inclination

W=mg =weight of the machine

F X =Fcosθ= horizontal component of the force

F Y = Fsinθ=vertical component of the applied force

Find the sum of forces at x direction ,∑ F X = F X - F γ = Fcosθ- µN …………………..1

 Find the sum of forces on –y direction

,∑ F y = F Y - W= Fsinθ- mg………………………………..2

The angle of inclination (θ) can be found from the height of the machine above the radius of
the wheel and the length of the machine.

H=1000mm

R=175mm

L=1500

Fig : representation of angle of inclination

By applying Pythagoras theorem the angle of inclination can be calculated

Where H = height of the machine, R = radius of wheel and

L = length of machine

tanθ= opp/adj = H−R = 1000−175 =0.55,θ= tan−1 0.55=28.80

L 1500

From equation (1) we have ∑ F X= F X - F γ = Fcosθ- µN= Fcosθ- µmg……….3

Where, = motive force

µ = coefficient of friction

Angle of inclination

m = mass of the machine

g = acceleration due to gravity

From Newton’s 2nd law of motion, we have have ∑ F X=ma …………………… 4

Therefore by equating equation (3) and (4), we can get

Fcosθ- µmg=ma
 Fcosθ=ma+ µmg

m(a+ µg) = Fcosθ

Fcos θ
m= …………………..…………..5
a+ µ g

To get the value of acceleration, let as assume the speed of the work starts from rest i.e. u=0

∆ V V −u 0.3 5−0
α= = = = 0.000012m/ sec 2
∆t t 3 0000

Tired wheels require a minimum traction force as their rolling coefficient is optimum above
20%

Therefore dry friction of coefficient of the soil is, µ=20%=0.2

From equation (5) we can find the mass of the machine

The horizontal component of the force ( F X =Fcosθ=240cos28.8 =210.31N but the

0

Horizontal component of the force to be maximum, θ=¿0 or cos θ =1

0
Fcos θ 240 cos 0
m= = =122kg
a+ µ g 0.000012+(0.2∗9.81)

4.2.3 Strength Analysis

The strength of the machine will be done by applying a force on the axle of the machine and
by considering the weight of the machine without hopper is distributed on the four wheels of
the machine with the resisting force of the wheels, hence the bending moment and shear force
will be found from this.

By assuming the total weight of the machine, the total weight of the machine without mass of
hopper becomes:

10 m
W=mg=122kg× 2 =1220N
sec

Axle wheel
 w m=1040 m

Fig : 3.5 geometry of the axle (shaft)

Where W=weight of the machine

Width of machine

RC and RD are the reaction forces on the right and left side of the frames

W W
n m y
4 4

V
+¿¿
M

A B

20mm RC 1000mm RD 20mm

n m y

Fig: 3.6 space diagram with loads

Take summation of moments at point A to get reaction forces

W
∑ M @ A=0= 4 *1040- R D*1020- RC *20=0

305*1040= R D*1020+ RC *20

R D*1020+ RC *20=317200…………................... (1)

And take summation of force in the vertical direction.

W W
,∑ F y = 0 = R D+ RC - - =0
4 4

R D+ RC =610

RC =610- R D…………………………………..2

Then put eqn. (2) in to eqn. (1) to get reaction force at point D.

1020 R D+20(610−R¿¿ D)¿=317200

 1020 R D-20 R D=317200-12200

1000 R D=305000

R D=305N

From eqn. (2) RC =610- R D=610-305=305N

After doing this we can get the moment at different points

1. Section near to point C, i.e. section n-n

W
V1
4
+¿¿
M1

To get shear force on this section take summation of force on the vertical direction.

W
,∑ F y = 0 = v 1+ =0
4

W
v 1= - = - 305N
4

v 1= v A =-305N

And to get the moment on the section take summation of moment.

W
∑ M @ n−n= M 1+ 4 *X=0
−W
M 1= *X= -305X, for 0≤X≤20mm
4

Therefore M C = M X (X=20)=-305*20= -6100Nmm

M A= M X (X=0) =0

Section near to point D, section m-m

W
X V2
4
+¿
M2 ¿

20mm RC
 To get shear force on this section take summation of force on the vertical direction.

W W
,∑ F y = 0 = RC −V 2- =0,V 2= RC - =305-305=0N
4 4

V 2=V C =0N

And to get the moment on this section take summation of moment

W
∑ M @ m−m= M 2 + 4 *X- RC (X-20) =0
M 2+305X- RC X+20 RC =0

M 1 =-305X-20*305+305X= -6100, for(20≤ X≤ 1020 )

= -6100Nmm
M 2=¿ M C

section near to point B, section y-y

W
X V3
4
+¿
M3 ¿

20mm 1000mm

RC RD

To get shear force on this section, take the summation of forces on y-direction

W
,∑ F y = 0 , RC + R D−V 3- =0,V 3=305+305-305=305N
4

V 3=V D=305N

And to get the moment on this section take summation of moment

W
∑ M @ y− y = M 3 + 4 *X- RC (X-20)−R D(X-1020) =0
 = M 3 +305X- RC *X-20 RC + R D*X-1020 R D

M 3=−305 X+305X-20¿ 305+305 X-1020*305=305X-6100-311100

M 3 =204X-311100, for 1020≤ X ≤1040

M D = M 3(X=1020)=305*1020-317200=-6100Nmm

M B = M 3(X=1040)=305*1040-317200=0Nmm

The above calculation of bending moments and shear forces can be summarized by the
following table. Finally taking a bending moment on the total length of the shaft to get
moment and shear forces

W W
1040mm
4 4

V M +¿¿

A 20mm C 1000mm D B

Taking moment at point B to get MA

W
∑ M B=0= M A + 4 ∗1040−RC∗1020−R D∗20=0
M A =305∗1040−305∗1020−305∗20=0

M A =0 Nmm

Take moment at point A to get MB

W
∑ M A =0= M B + 4 ∗1040−RC∗20−R D∗1020=0
M B =305∗1040−305∗1020−305∗20=0

M B =0 Nmm

To get shear force at point B, take summation of the forces at y = 0

W W
,∑ F y = 0 , RC + R D−V - - =0
4 4

V=305+305-305-305=0
 V=V B=0 N

Table : bending moment and shear force

Bending moment Shear force

at point A M A =0 Nmm v A =-305N
at Point B M =0 Nmm V B=0 N
B

at point C M C = -6100Nmm V C =0N

at point D M D = -6100Nmm V D=305N
By using the above data, the combined bending moment and shear force diagram can be drawn

305N 305N

A 20mm C 1000mm D B

305N 305N

1040mm

Vertical load diagram

+305N

A C D B

-305N

Shear force diagram

 A C D B

-6100Nmm -6100Nmm

Bending moment diagram

Fig. vertical load diagram, shear force diagram, vertical bending moment diagram

From the above diagram it can be conclude that the maximum bending moment is located at
point C and D i.e. M (max) =|-6100|Nmm=6100Nmm and the maximum shear force is located
at point D, i.e. =305N

4.3 DETAIL DESIGN

In this part design, the different part of the machine will be designed. The components that the
machine consists are shaft, frame, pulley, v- belt, wheel, bearing, cutter and cam.

The above components will be designed and selected according to bending, torsion and shear
stresses and special dimensions of the part will be found from strength analysis of the parts.
Some the materials will be selected from the standard without any analysis.

4.3.1 Design of Belt

Let us find the length of the belt, Let r1and r2 =radius of larger and smaller pulley

X=distance between the center of two pulley

L=total length
2
(r 1 −r 2)
L= (r1+r2) +2x + ………………. (1), in terms of pulley radii
x

2
= π ( + )+2x+ (d 1−d 2) ……………… (2), in terms of pulley diameter
L 2 d1 d2 4x
Fig : Representation of tension force and dimension of v-belt

We have the diameter of d 1 larger pulley, d1=180mm and the diameter of pulley d 2=90mm and
let us take center distance X=250mm, then by taking from equation (2) we get
2 2
π (d −d ) π (180−90)
L= (d 1+d 2)+2x+ 1 2 = (180+90)+(2*250)+
2 4x 2 4∗250

L= 924.115+8.1=932.215mm

Let as get the width of the pulley

Let b=width of the belt in mm

T1=tension in the tight side of the belt

T2 =tension in slack side of the belt.

We know that power transmitted in (p)

P= (T1-T2) V, Where P=0.75kw and V=0.5m/s

75w = (T1-T2)0.35

T1-T2=214N……………………. (1)

We also know that 2.3 log(T 1-T 2)= μθ……… (2)

Since we select fabric belt and the coefficient of friction is typically in the range of 0.20 to
0.25.

Therefore take as μ=0.23

The angle of rap ( ) for an open belt can be found as follow:

r 1−r 2 90−45
sin α = = =0.18,α =sin−1 0.18 = 10.370
X 250

π rad= -2* π rad =

θ =¿ ¿-2α ) ¿ 10.37 )
0
2.78
0
180 180

Then from equation 2 we have 2.3log (T1/T2)=0.23*2.78=0.64

LogT1/T2=0.64/2.3=0.278 or T1/T2=1.9…………….. (3)

Therefore by equating (1) and (3)

We get T1=451.78N and T2=237.78N

Consideration of centrifugal tension assuming fabric belt for which the density may be taken
as 1220kg/m3 and assuming the thickness of the belt is 10mm.

We know that the cross sectional area of the belt

A=b*t

=b*10=10bmm = 0.01bm

Mass of the belt per meter length

m=area*length *density

Where L=932.215mm=0.932m

m= 0.01bm*0.932m*1220kg/m3=11.37bkg/m

We know that centrifugal tension TC=mV2=11.37b*0.352=1.39b

The maximum tension in the belt,T=σ ×b×t

σ =1.75Mpa

Therefore T=1.75*b*10

T=17.5bN

We know that tension in the tight side of the belt (T1) =T-TC

451.78=17.5b -1.39b =16.11b

 b=28mm, the standard width of belt is 30mm

Then mass of belt m=11.37*bkg=11.37*0.03=0.34kg

4.3.2 Design of Cast Iron Pulley

The outer diameter of the larger pulley is assumed to be half of the diameter the larger wheel
to have enough clearance from the ground.

diameter d = d w = 350 =175mm, where, d = the wheel diameter =350mm

The pulley 1
2 2 w

Therefore, the standard diameter of pulley d1=180mm

Let the diameter of the smaller pulley d2/2=90mm

If the width of the belt is known, then the width of the pulley or face of the pulley (B) is
taken 25% greater than the width of belt

According to Indian standard, is 2122 (part 2) -1973 (reformed1990), the width of pulley is
forced the following table

Table : standard width of pulley

Belt width in(mm) Width of pulley to be greater than belt

width in( mm)
Up to 125 13
125-250 25
250-375 35
475-500 50
= +13mm=30mm+13mm=43mm
Therefore the width of pulley is w p w b

D D
The thickness of the pulley rim (t) varies from +2mm to +3mm
300 200

For single belt the diameter of the pulley (D) in mm, the thickness of the larger pulley is

d1 180
Then t= +3mm= +3mm=3.9mm
200 200

The thickness of the smaller pulley

 d2 90
t= +3mm= +3mm=3.45mm
200 200

Dimension of hub

The diameter of the hub ( ) in terms of shaft diameter (d) may be related by the following
relation.

d h =1.5d+25mm=1.5*30+25mm=70mm, Where d=shaft diameter

L= π *d= π *30mm=47mm
The length of the hub 2 2

Dimension of arms
The number of arms may be taken as 4 for pulley diameter from 200mm to 600mm and 6 for
diameter from 600mm to 1500mm.

Since our pulley diameter is less than 200mm, then it has no arms i.e.it is made with solid disc
instead of arms. The thickness of the solid web is taken equal to the thickness of rim measured
at the length center of the pulley face. [2] p720-721

But we need to use four arms even if the pulley diameter is less than 200mm in order to

 Decrease the weight of the pulley as well as the

machine.

 Decrease the stress concentration on the pulley.

Let us use three belts in order to increase the speed of the cutter, and then we have three
pairs of pulleys. The speed of the first pulley in the same or the speed of the wheel i.e.
N1=17.05rpm.Then the speed of the rest pulley in found from velocity ratio
consideration.

We have N1=17.05rpm, d1=180mm, d2=90mm

Then the speed of the second pulley N2 can be found the following relation

N 2 d1 d1 180
= , N 2= N 1* =17.05* =34.1rpm
N 1 d2 d2 90

Next let us find the speed of the second pair of pulleys

i.e.N3, N4 Let d1=d3 and d2=d4, and N2=N3 =34.1rpm

And from velocity ratio of the second pair of pulley we have

 N 4 d3 d3 180
= , N 4 = N 3* =34.1* =68.2rpm
N 3 d4 d4 90

To find the speed of the third pair of pulley let d5=d1 and d6=d2 then we have

N 5= N 4 =68.2 rpm

And from velocity ratio of the third pair of pulley we have

N 6 d5 d5 180
= , N 6= N 5* =102.28* =136,4rpm
N 5 d6 d6 90

Therefore the required speed of pulley as well as the cutter is increased from 17.05rpm to
136.4rpm

Mass of larger pulley= ρ *v

2 2
π D *t= π∗0.18 *0.0039=9.92* −5 3
v=A*t= 10 m
4 4

The density of cast iron pulley =7200kg/m3

7200 kg
m p 1= 3 *9.92*10−5 m3=0.714kg
m
2
m
Weight of larger pulley,w p 1=m p 1∗g =0.714kg*10* 2 =7.14N
s

2
Mass of smaller pulley, m p 2= ρ∗v = ρ *A*t= ρ * π * d *t
4

2
m p 2=7200* π * 0.09 *0.00345=0.158kg
4
2
m
Weight of smaller pulley w p 2=m p 2∗g=0.158kg*10* 2 =1.58N
s

4.3.3 Design of Frame

From the available data, let us determine the dimension of frame. Let us say our frame has a
length of 1500mm with width of 200mm and thickness of 20mm.

From the available data, let us determine the dimension of frame.

Actual length of frame=1500mm
l 1500
Equivalent length, Le = = =¿750mm for the frame both ends are fixed
2 2

C= Constant, representing the end conditions of the column or end fixity

coefficient. Taking C=4

σ cr =crushing stress for mild steel is 330Mpa

2 2
C∗π ∗E π ∗210000 Mpa
σ
The crushing stress is given by cr= Le 2 = Le
2
=330Mpa
( ) ( )
k k

Le
=79.25
k

Le L 750 mm
=79.25, Le =750mm then k= e = =9.46mm,and k 2=89.49mm 2
k 79.25 79.25

200mm

20mm
3 3
I xx = b h = 20∗200 =13.33*106 mm 4
12 12
3 3
I yy = h b = 200∗20 =13.33*104 mm 4
12 12

Since I yy is less than I xx ,therefore the frame will tend to buckle in Y-Y direction. Thus we
shall take the value of I as I yy =13.33*104 mm 4

Then the critical load is found as

2 2 5 4
C∗π ∗EI 4∗π ∗2.1∗10 13.33∗10
Pcr = 2
= 2 =1964.7KN
Le 750

Since the critical load value 1964KN is greater than the weight of the machine value 1220N

The design of frame will be safe.

Where critical load

=crushing stress
 4.3.4 Design of Shaft
The shafts may be designed on the basis of strength rigidity and stiffness
In designing shafts of the basis of strength, the following cases may be considered that is
the shaft will be designed by considering the following.

Shaft subjected to a twisting moment only

Let as find the diameter of the shaft when the shaft is subjecting moment (torque) only

T τ ………………1
We know that =
J r

Where: T e=equivalent twisting moment or torque acting on the shaft.

J=polar moment of inertia of the shaft about the axis of rotation.

τ =¿ Torsional shear stress and

r=diametric distance from neutral axis to the outer most fiber.

We know that for round solid shaft, polar moment inertia.

π 4
J= ∗d
32

And r=d/2, where d=diameter of the

shaft. Equation (1) can be written as
π
T e= = τ∗d 3…………….. 2
16

Let as use a material for shaft of carbon steel of grade 40c8with σ u=560Mpa and σ y=320Mpa

According to (ASME) code for the design of the transmission shafts, the maximum
permissible working stress in tension or compression may be taken as

σ t=112Mpa, for shafts without allowance for key ways

σ t=84mpa for shafts with allowance for key way or

σ t=0.66el or 0.36 whichever is less

The maximum permissible shear stress may be taken as: τ=56mpa for shaft without
allowance for key ways and τ =42mpa for shafts with allowance for key ways or
We know that the allowable shear stress for the shaft material can be found as

σu 560 Mpa
τ= = =40Mpa
2F .S 2∗7
 Where σ u=560Mpa for carbon steel grade 40c8
F.S=7 taking a factor of safety of 7

Then from the above equation (2) we can find the diameter of the shaft by considering
twisting of the shaft. From the above equation (2) we have,

T e=√ M 2+T 2=√ 61002 +42000 2=42440.67Nmm

π 3 π 3
T e= τ∗d =42440.67Nmm= 40∗d
16 16

3 42440.67∗16
then , d = , d=28mm
40 π

Shaft subjected to bending moment only

When the shaft is subjected to bending moment only, then the maximum stress is given by

M σb
= …………………………………. (1)
I y

Where M e=equivalent bending moment

I=moment of inertia of cross sectional of shaft

σ b =bending stress

y=distance from neutral axis to the outer most fiber

we know that for round solid shaft, moment of inertia

π 4
I= ∗d and y=d/2 substitution in equation (1) we have
64

π 3
Me = ∗σ b∗d ……………………. (2)
32

From this equation obtain the diameter of the shaft for carbon steel grade 40c8 we have σ tu
=560- 670Mpa

Assuming factor of safety of 7 and taking σ tu=560mpa the permissible tensile stress is given
σ tu 560
by σ t or σ b= = =80Mpa
F .S 7

π 3
From equation (2) above we have M= 32 ∗σ b∗d
We have the maximum bending moment, M=6100N-mm

Substituting the above values we can get the required diameter of the shaft

1 1
M e= ( M + √ M 2 +T 2)= ¿)
2 2

1
= ¿67)
2

=24270.3Nmm

π
Me = ∗σ b∗d
3
32

π 3
24270.3Nmm= ∗80 Mpa∗d
32

24270.3Nmm*32= *(80)*d3

24270.3∗32
3
d = =3090.2,d=√3 3090.2 =15mm
π∗80

Therefore taking the maximum of the two the diameter of shaft is d=28mm say 30mm.

Mass of shaft = ρ∗v , Shaft made of carbon steel with density of 7853kg/m
3

2
πd
v= A∗L= L= π∗¿¿ =6.59*10−4 m3
4

7853 kg
m= ρ∗v = 3 *6.58*10−4 m3 =5.18kg
m

Where L= length of shaft =1000mm

A =area of shaft

v = volume of shaft

ρ =density of shaft material

4.3.5 Design OF KEY
The purpose of key is to fasten pulley with the shaft and another parts. Let us use a
rectangular sunk key that is made of steel with shearing stress of 42mpa.the usual
proportion of this key are:
Width of key, w=d/4 and thickness of key, t=2w/3 or d/6
Where d=diameter of the shaft
The standard dimensions of key for 30mm diameter plate are width of key,
w=30mm/4=7.5mm=10mm, thickness of key t=2*10mm/3=6.67mm=8m
Therefore w=10mm and t=8mm

Fig : geometry of rectangular sunk key

Strength of sunk Key

A key connecting the shaft and hub is shown above

Let T = Torque transmitted by the shaft,

F = Tangential force acting at the circumference of the shaft,

d = Diameter of shaft,

l = Length of key,

w = Width of key. t = Thickness of key,

τ and σ c = Shear and crushing stresses for the material of key.

A little consideration will show that due to the power transmitted by the shaft, the key may fail
due to shearing or crushing.

Considering shearing of the key, the tangential shearing force acting at the circumference of
the shaft, F = Area resisting shearing × Shear stress = l∗w∗τ
Therefore Torque transmitted by the shaft,

d l∗w∗τ∗d
T=F* = ………………..1
2 2

Considering crushing of the key, the tangential crushing force acting at the circumference of

F = Area resisting crushing × Crushing stress = l∗t ∗σ

the shaft, 2 c

Torque transmitted by the shaft,

l∗t
∗σ c∗d
T=F* d 2 ………………..2
=
2 2

The key is equally strong in shearing and crushing, if

l∗t
∗σ c∗d w σ
l∗w∗τ∗d 2 or = c …………3
= t 2τ
2 2

The permissible crushing stress for the usual key material is at least twice the permissible
Shearing stress. Therefore from equation (3), we have w = t. In other words, a square key is
equally strong in shearing and crushing.

In order to find the length of the key to transmit full power of the shaft, the shearing strength
of the key is equal to the torsional shear strength of the shaft.

We know that the shearing strength of key,

l∗w∗τ∗d
T= ………………4
2

And torsional shear strength of the shaft,

π 3
T= ∗τ 1∗d ……………………….5
16

(Where τ 1 =¿ Shear stress for the shaft material)

l∗w∗τ∗d = π 3
From equation (4) and (5) we have, ∗τ ∗d
2 16 1
 π 2 π∗d
∗τ 1∗d ∗τ 1
8 2 d∗τ 1 …….taking w= d ……….6
l= = =1.751 4
w∗τ τ τ

When the key material is same as that of the shaft, then τ =τ 1

l=1.751 d

The length of the key is obtained by considering the key in both shearing and crushing.

We have w=10mm and t=8mm

Let length of key

Considering shearing of the key, we know that the shearing strength or torque transmitted (T)

l∗w∗τ∗d
T=
2

Where τ =¿ shear stress for cast iron pulley we need to select a steel key with a shearing and
crushing stresses for the key material are 42Mpa and 70Mpa

l∗10∗42∗30
T= =6300l N………….(a)
2

And torsional shearing strength (or torque transmitted) of the shaft,

π π
∗τ ∗d = T= ∗42∗30 =222660Nmm………(b)
3 3
T= 16 1 16

From equation (a) and (b), we have, 6300l N=222660Nmm

222660
l= =35.34mm
6300

Now considering crushing of the key, we know that shearing strength (or torque transmitted)
of

the key,

l∗t l∗8
∗σ c∗d = ∗70∗30 =4200 N…………..(c)
T= 2 2 l
2 2
From Equating (b) and (c), we have, 4200l N=222660Nmm

222660
l= =53mm
4200

Taking larger of the two values, we have length of key, l=¿ 53mm Ref [2] Page (470-474)

4.3.6 SELECTION OF BEARING

Specification of ball bearing
The basic static load rating (Co ) in Newton’s for ball and roller bearings may be
obtained as follows: For radial ball bearings is given by [Co ]Where; i = Number of
rows of balls in any bearing, α = Nominal angle of contact (angle between the line of
action of the ball load and a plane perpendicular to the axis of the bearing) , z =
Number of balls per row, f o=Factor depending upon the type of bearing ( 12.3, for
radial contact and angular contact groove ball bearings made of hardened steel, and D =
Diameter of balls =7.5mm
c o =f o∗i∗z∗D cos α ……………….1
2

2 0
c o =12.3∗1∗15∗7.5 cos 15 =10KN
Static equivalent load for roller contact bearing

Static equivalent radial load for ball or roller bearing under combined radial and axial
or thrust load is given by the greater magnitude of the obtained by the following two
equations: W= X O∗W R +Y O∗W A …………2
Where WR=Radial load, XO =Radial load factor, WA= Axial or thrust load, YA = Axial or
thrust load factor. For radial contact grove ball bearing having single row and α=15˚,
XO=0.5 and YO=0.46:
W=0.5*816N+0.46*0=408N
Life of bearing: The life of an individual ball (or roller) bearing may be defined as the
number of revolutions (or hours at some given constant speed) which the bearing runs
before the first evidence of fatigue develops in the material of one of the rings or any of
the rolling elements.

Basic dynamic load rating for rolling contact bearing

Basic dynamic load rating in Newton’s for ball or roller bearings may be obtained
as follows: for radial and angular contact ball bearings, except the filling slot type,
2
with balls not larger than 25.4mm in diameter is given by C= f (icos α )0.7∗Z 3∗D1.8
c

Dynamic equivalent load for ball bearing:-Dynamic equivalent radial load for radial
or angular contact bearings, except the filling slot types, under combined constant
radial load and constant axial or thrust load is given by
 W= X∗V∗W R + Y∗W A………………3

Where V is a rotation factor, 1 for all types of bearings when the inner race is rotating
W=1*1*816+0*0=816N
Dynamic load rating for ball bearings: - the approximate rating of life (or service)
life of ball or roller bearing is based on the fundamental equation
K
C
L=( ) ∗106 revolutions … … … … … … … 4
W
L = Rating life, W = Equivalent dynamic load, C =Basic dynamic
load rating k =3 for ball and 10/3 for roller bearings.
The relationship between the life in revolutions (L) and the life in working hours (LH) is given
by L=60N* L H ………………….5 , Where N=speed in rpm
The life from the standard table of the bearing in hours, LH = 20 000 hours, and life of
the bearing in revolutions become,
L=60*54.3rpm*20000hr=65.16*106 rev

Therefore the basic dynamic load rating (c) is;

6 1
65.16 10 3
c=816∗( 6
) =4.02KN
10
Basic dynamic load radial capacity C; C=c¿ K s =4.02*2=8.04KN

Where KS=2, service factor for radial bearing having moderate shock load

Read using the values of the (CO = 10kN) & (C = 8.04kN) from the Basic static and dynamic
capacities of various types of radial ball bearings then the bearing number is 206. Therefore
the bearings dimension is obtained from table number 7 below the Principal dimensions for
radial ball bearings.

Therefore for Bearing number=206, Bore= 30mm, outside diameter=62mm, Width= 16mm

4.3.7 SELECTION OF WHEEL

Let us assume the outer diameter as 350mm which is good enough for the machine to move
freely on the ground.

Then the inner diameter become

d o =d i +2t=350 mm ,t=20mm

350=d i+ 2∗20

d i=350−40=310 mm

Let us find the diameter of the rim, d r =d i +t =310+20=330mm

4.3.8 DESIGN AND SELECTION OF CUTTER

The cutting unit, which was attached to the main frame, has two-knife bar sections; the

upper one reciprocates over the stationary bottom one. The stroke length and the width

of the standard type knife are 50.8 mm and the standard length of the cutter is 67mm.
50.8mm,n = L = 1000 mm =19.685, this is the
Therefore stroke length or width, w= c
W 50.8 mm
total number of cutters that are mounted on a one meter long cutter bar.

Let us use 19 cutters by letting some clearance for the cutter bar to be mounted in to the
frame of the machine and to reciprocate freely.

The number of cutters used=19

The cutter is made of steel with an oblique angle of 30º and smooth knife edge to decrease the
shearing strength of wheat stalk or to harvest at minimum force.

67mm

50.8m

50.8mm

Fig : Geometry of a single cutter

SN
The knife speed was calculated using V K = 30

=knife speed( m )
Where V K s
 S=stroke length(m)=n*w=2.5*50.8=126mm
N=crank speed (rpm), in our case the crank speed is equal to the speed of the last
pulley=204.56rpm
SN = 0.126∗204.56 mrpm 0.965 m m
V K= ¿ = ≈1
30 30 S s

We have force applied F=160N and the final rotational speed produced to the cutter is,
2 πN 2∗π∗204.56
N=204.56rpm then ω= 60 = 60
=21.42 rad / s

rad
The cutting speed become v=ω∗r =21.42 s ∗0.045 m=0.9464 m/s ≈1 m/s

Where r =radius of the smaller pulley

N∗1 m
The output power is p=F∗v=160 =160 wat =0.16Kw
s

60 P 60∗160 wat =7.5Nm

T= =
The torque produced by the cutter become 2 π N 2∗π∗204.56 rpm

Shearing strength of the cutter

The shear strength of the cutter must be calculated to compare with the shear strength of the
grain stem (wheat, barely….etc.), this is needed because shearing strength of the cutter is
important for the grain stem to be cut.

Let us find the area of wheat straw with average outer diameter of 5mm and thickness of
0.1mm

d o =5 mm ,t=0.1mm ,d i=d o−t=5−0.1=4.9 mm

Therefore the area of wheat straw becomes

2 2
π (d o −di ) π (52−4.92)
A= = =0.7775mm 2
4 4

The shear strength produced by each cutter on a single wheat straw is

F 160 N
τ= = =205Mpa
A 0.7775 mm 2

The shear strength produced by the total cutter on a single wheat straw becomes
 F 160 N 160 N =10.83Mpa
τ= = =
n∗A 19∗0.7775 mm 14.7725 mm
2 2

The shear strength produced by the total cutter while cutting two wheat straws becomes

F 160 N 160 N =5.45Mpa

τ= = =
n∗2 A 19∗2∗0.7775 mm2 29.545 mm2

Where n = number of cutters

F = force applied to the cutters

Let us calculate the cutting area of the cutter, (A) from the profile of the cutter shown below.

Let y=length of blade, W=width of cutter=50.8mm and oblique angle=30˚

w
Then 2 25.4
tanθ= , y= =44 mm
y tan 30
0

Then from area of triangle, we have A=(1/2)LW=(1/2)*Y*W

=0.5*44*50.8=1117.6mm 2

It can be concluded that each cutter can cut two wheat straws because the shearing strength of
the cutter while cutting two wheat straw is much more greater than that of the wheat straw, or
36 wheat straws can be cut in each reciprocation of the cutters. It is known that a blade with
oblique angle of 30º does not cut all of the straws entering in to the cutters at each stroke; it
will cut the wheat straws step by step in a continuous harvesting. Therefore the designed
machine is effective from the subject view of shearing strength.

The shearing strength of wheat straw varied from 3.25 to 3.86mpa, which is found from some
experimental analysis shown below.
Shearing property of wheat stem
Shearing stress of wheat stalk was measured for four moisture content levels (15, 25, 35 and
45% , ), three cutting heights (100, 200 and 300 mm), two types of cutting knives, smooth
and serrated edge and three blades oblique angle (0, 15 and 30 deg.). The results of data
analysis showed that the shearing stress of wheat stems decreased as the moisture content
decreased. The shearing force of stems, decreased as the cutting height of stalk increased,
because of a reduction in stalk diameter. Shearing stress was lower by using smooth edge
knife, because of less friction than serrated one. The blade oblique angle of 30 degree showed
the least shearing stress. The average of shearing stress varied between 3.25 and 3.86MPa.
Bending stress and modulus of elasticity increased as the moisture content decreased and
decreased as the cutting height of stem increased. The average of bending stress varied
between 17.74-26.77MPa and modulus of elasticity varied between 3.13-3.75Gpa.

Effect of knife type and oblique angle on stem shearing stress

Greater engagement of the serrated edge knife with the stem than smooth one and the increase
of friction were the main causes to increase shearing stress by 7%. Comparing the three blades
oblique angles (0, 15 and 30 degrees), the 30-degree one had the lowest while the 0-degree
oblique angle had the maximum force requirements. The effects of oblique angle can be
explained by the change of contact area between the knife and the stem while cutting has
accrued and by the physical properties of stem tissues. The relation between shearing stress in
and oblique angle by using smooth and serrated edge knives could be found as Eq. (1)
and Eq. (2),
2
Respectively τ smooth=3.75−0.2 A+ 0.002 A ……..1
2
τ serrated =4.1−0.03 A+ 0.003 A ……..2

Where A=oblique angle (deg.)

Table .Effect of oblique angle on shear strength of wheat

Oblique angle (deg.) Shearing stress ( )

0 3.92
15 3.58
30 3.36
Effect of Moisture Content on Stem Shearing Stress
The value of shearing stress at low moisture content was approximately 19% lower than at
high moisture contents.

This result was also reported for wheat straw, sunflower stalk and barely straw. The average
shearing stresses were found 3.25, 3.57, 3.69 and 3.86MPa for moisture contents 15%, 25%,
35% and 45% ., respectively. The moisture content had a significant effect on the shearing
stress at 1% probability level.

An exponentially relationships, between shearing stress and moisture content, reported by

previous researchers. Eq. (3), (4) and (5) shows relation between shearing stress, ( ) and
moisture content, %w.b., (MC) at the stem cutting height of 100, 200 and 300 mm,
respectively.

τ H =4.15+ 0.001 MC −0,003 M C 2 … … … … … … .3

100

2
τ H =3.95+0.002 MC−0,003 M C … … … … … … .4
200

2
τ H =3.61+0.002 MC−0,003 M C … … … … … … … 5
300

Table3.6: effect of moisture content on shear strength of wheat

Moisture content ( ) Shearing strength

15 3.25
25 3.57
35 3.69
45 3.86
Effect of cutting height on stem shearing stress

The shearing stress was decreased with increasing of cutting height. This result was also
reported by others. In terms of plant height, most of the wheat varieties were statistically
significantly different from each other. With increasing the cutting height from 100 to 300
mm, shearing stress will be reduced by 13%. With increasing the stem height, stem diameter
will be decreased in the range of 5.1 to 7.5 mm

Table3.7: Effect of cutting height on shearing strength of wheat

Cutting height (mm) Shearing stress

100 3.80
200 3.62
300 3.35
We can conclude that as the cutting height of the wheat stalk increased shearing force of stalk
decreased because of reduction in stalk diameter. The average of shearing stress varied
between 3.25 and 3.86 . Taller plants, however, have lower stem diameters and shearing
energy will be decreased. Shearing stress is lower by using the smooth edge, because of less
friction than serrated one. The oblique angle of 30 degree showed the least shearing stress.
Selection of knife type plays a significant role in economizing on cutting force requirements.
So selection of suitable oblique angle of the knife decreases the shearing force of wheat stems.

From this we can conclude that the cutter of the machine with 30º oblique angle and smooth
knife edge has shearing strength much greater than that of wheat stem for all operating
conditions i.e. moisture content, cutting height, oblique angle and knife type. Therefore the
machine can perform its intended work or the cuter can cut the wheat stems by withstanding
the shear strength produced of view of shearing strength by them. Hence the machine or the
cutter is safe from the subject point.

4.4 WORKING PRINCIPLE

The machine which is designed in this project is a manually operated multi cutter grain
harvesting machine that can be operated by single person by pushing it. It can be pushed by
using the applied force of human when the person pushes the machine; the rotational motion
of the wheels is obtained. Three pair of pulleys and belt drives is used to multiply the
rotational speed of the wheels in order to bring higher speed for the cutters. Cutters are
attached at the front position of the machine with the cutter bar. The cutters can be
reciprocating and cut the grain, therefor a slot profile formed on the cylinder which is inserted
on the shaft is used to convert rotational motion of belts to reciprocating motion of the cutters.
The slot is placed on the front wheel of the shaft at middle distance of the shaft from both
ends. The bar is placed parallel to the slot profile; it is attached to the cutter bar and inserted
on the slot profile made on the cylinder. By using this mechanism the rotational motion of the
machine can be changed in to reciprocating motion of the cutter bar in order to cut or harvest
the grain