CHAPTER 1

INTRODUCTION

1.0 INTRODUCTION

This paper exhibits the useful necessities, plan, and fabricate of the commercials grass

cutting and collecting machine. The outline is one of its kind that encourages both the

cutting and collecting of the industry grass typically more than 4 feet long (Aaqib

Gulzar Khan1, Adeel-ul-Haq Qurishi, n.d.). The benefit of this framework is that

separated from cutting the grass it encourages the development of bundles, with no

loss of grass emerging because of dispersing of grass by stable cutting powers, which

can be gathered appropriately. Consumption resistance, quality, solidness, and

hardness are important parameters for real determination of edges.

A grass cutter is a machine that utilizations rotating sharp edges, to cut a farmland

arrive spaces, at an even length. Grass cutters utilizing a sharp edge that pivots about a

vertical hub are known as cutters, while those utilizing an edge gathering that about an

even hub are known as chamber or reel cutters. Numerous unmistakable arrangements

have been made, each suited to a specific reason. The littlest sorts, pushed by a human

vitality, are reasonable for little dairy cultivating land, while bigger, independent,

rideon cutter machine are appropriate for huge land, and the biggest, multi-pack cutter

machine for the most part hauled behind a tractor, are intended for huge fields of

grass, for example, dairy cultivating land which is up 100 hectares.

1
1.1 PROBLEM STATEMENT

Based on current observations, we can identify the problem statement related. The first

is that most of the existing machines usually take a long time to complete the process

of harvesting (Cook & McGhee Jr, 1994). The involvement of many laborer also is a

main problem that can be seen today in the dairy industry in Malaysia. Therefore, the

rate of payment for each worker was very high especially the economic situation in

our country can be said unstable (Wong, Rajion, Leong,

Ebrahimi, & Goh, 2012)

1.2 AIM

The target of this project is to design and innovate the existing product to ease the

harvesting process for ruminant feed

1.3 PROJECT OBJECTIVE

The objective of this project is:

1. To identify the types of machines available in the market to harvest or to cut

the Napier grass.

2. To propose an effective and efficient technique for harvesting the Napier grass

for ruminant feed

3. To develop a prototype of a machine to harvest and to chop the lawn Napier

grass for ruminant feed.

2
1.4 SCOPE

The scope of this project will focus on dairy farming in Malaysia, because the results

of livestock production in the country are worsening. It is said to be an issue for

livestock farmers because it can affect the health of livestock and thus reduce the

production of livestock-based products like milk, fertilizers, etc. (Chye, Abdullah, &

Ayob, 2004). This project also focusses on fabrication of the prototype Napier grass

cutter to reduce the time taken from harvesting process.

1.5 METHOD

1.5.1 Design

The cutter used is a sharp blade that cuts the grass with high-speed rotation. The

highspeed rotation of the blades along with the centrifugal force acted on it due to its

minimal weight enable the Napier grass blown into the container without using human

energy. Based on the existing product, most of the products that can only be

completing one at work such as starting with cutting grass process and then move to

chopping process. Therefore, this project focuses on combining two processes in one

machine to save the process time to prepare the ruminant feed.

3
 1.5.2 Fabricate

1. Autodesk Inventor Software

In Autodesk Inventor, the parametric part modelling process is to create a rough two-

dimensional sketch of the basic shape of the base feature of the design. Apply and

modify constraints and dimensions to the two-dimensional sketch (McFarlane, 2017).

Other than that, to extrude, revolve, and sweep the parametric two-dimensional sketch

to create the base solid feature of the design. Add additional parametric features by

identifying feature relations and complete the design. Perform analyses on the

computer model and refine the design as needed. Lastly to create the desired drawing

views to document the design.

2. CNC milling machine

Milling is a cutting operation with a geometrically specified cutting edge in which the

tool makes the rotating main movement, and the feed as well as the indeed movement

are generally made by the work part.

3. Lathe Machine

The lathe is one of the most important machine tools in the metalworking industry. A

lathe operates on the principle of a rotating workpiece and reciprocating cutting tool.

A lathe machine, which is used to remove metal from the workpiece to required shape

and size

4
1.6 IMPACT FROM PROJECT

The impact of which could be implemented through this project is to ease works

cutting grass with very rapid rates. At the same time can reduce the cost of certain

costs such as fuel per engine or vehicle involved in the process of harvesting grass or

other names Napier grass. Other than that, the safety factor is also included in this

subtopic. With there is any product like this, then concerns over the safety of workers

can be reduced. The best approach is to focus on plant management techniques that

are environmentally friendly and less harmful to use the tools such as machetes and

sickles to improve the quality and safety of farmers.

5
 CHAPTER 2

LITERATURE REVIEW

2.0 HERBACEOUS PLANTS

In Malaysia, we have many species of grass suitable for grazing. The grass that we

usually see in the area of culture is like Napier grass or its scientific name which is

Penisetum purpureum, Guinea or Panicum Maximum, rice with scientific name

Brachiaria Nautica and more. Tree nuts are also widely used outside the country and

most of them are in our country Petai Grasshopper or Luecaneae Leucocephala, and

Gliricidia sepium, etc.

Napier grass or its logical name Pennisetum purpureum is one of the herbaceous

plants which typically utilized as a part of the dairy cultivating division. It is likewise

called as elephant grass since it can develop to 4 meters tall and it is quick growing

(Orodho, 2006). The ruminant region in Malaysia is very little made, which is

inferable from confined snacking field, suboptimum field quality, and smallholder

control

The significance of Napier grass (Pennisetum purpureum) can be seen from the part it

plays as the real domesticated animals nourish in small holder dairy generation

frameworks. The ruminant sector in Malaysia is not well developed, which is

attributable to limited grazing grass land, suboptimum pasture quality, and small

holder domination. Malaysia’s food self-sufficiency did not show significant

improvement in recent years. Malaysia produced only about 4.67% dairy products,

9.03% lamb/mutton and 24.07% beef (Wong et al., 2012).

6
2.1 NAPIER GRASS AS RUMINANT FEED

Napier grass is one of the popular grasses which are usually harvested at the short

interval to feed at an early growth stage because the nutritive value of the grass is

good for ruminant. Napier grass much-favoured livestock/ruminant in view of the high

nutritious esteem. Nutrient content of Napier grass are divided into 19.9% of dry

matter, 10.2% crude protein, 1.6% fat, 34.2% crude fibre(CP), 11.7% ash, and 42.3%

extract materials without nitrogen (Vieira, Pereira, Malafaia, & de Queiroz, 1997) ,

The results of numerous studies leave that Napier grass or another name the elephant

grass has a complete nutritional requirements and in accordance for the ruminant feed.

Figure 2.1: Napier grass for ruminant

http://www.biostart.co.nz/products/animal-probiotics/ruminant/

The most important nutrients from the leaves of grass that are nitrogen and protein

content. Also in Napier grass (elephant grass) leaves also have fibre and vitamins that

are high enough. Ruminant feed from Napier grass usually comes from young leaves,

because of the added good digestibility which is about 70 percent (Orodho, 2006).

7
While the older leaves, power digestibility only live 50 percent. In addition, young

leaves contain a lot of water.

2.2 THE DESIGN AND FABRICATION

Around 90’s, harvesting of the grasses in dairy sector for ruminant feed was done by

machete or cutlass only (Aaqib Gulzar Khan1, Adeel-ul-Haq Qurishi, n.d.). This

method for manual cutting was arduous as well as tedious as it is human exertion that

is altogether required both for cutting and movement. There was no also inaccuracy in

cutting the level of the each inaccuracy in cutting the level of the each individual as

any factors will influence the late, speed, height of the cut each Napier grass. Apart

from all these old methods of the cutting, there is also the risk of an accident. As one

can easily get cut with the cutter and chopper equipment. Also, there are requirements

for mechanization since the world is going modernization bearing all these problems

in mined trying to find a solution to it.

Figure 2.2: Harvesting using manpower

http://hub.africabiosciences.org/blog/category/animal-feed/

8
In application of Napier grass cutter machine in any dairy farmer field and farm land

causes seriously reduction in number of labour needed in the harvesting of the Napier

grass, however with the aid of Napier grass cutter machine, the job is easily performed

without much wasting of time. This Napier grass cutter machine can get the grass

well cut and chopped to make as ruminant feed. Other than that, a local farmer can

embark on harvesting of up to 100 hectares of farm land with the aid of Napier grass

cutter machine. This project will reduce the burden of the farmer to embark on the

farming (harvesting) operation. Also, many people will develop interest and render

agricultural engineering or course related to farm

9
2.3 EXISTING PRODUCT/MACHINE

2.3.1 Napier Grass Chopper (semi machinery)

Figure 2.3: Napier grass chopper

http://www.weiku.com/Farm-Machinery/buy-Napier-Grass-Chopper.html

2.3.2 Overview

Base on the entire steel structure, it is having small body shape and light, easy to move

and it is portable. Including an extraordinary gadget to guarantee the safety when or

on working the cutting process. Furthermore, the grass roller receives cross shaft, and

has the upside of minimized structure, running readiness, straightforward introducing.

Besides that, it’s have Multi-decision on power, engine, diesel motor and tractor are

better. It particular suit for the electric rare range. The edge receives amazing steel,

10
through exceptional innovation handling, it is Super Wear-Resistant and settled by

high quality rush to guarantee the wellbeing when running.

2.3.3 Specification

Table 2.1: Napier Grass chopper specification

http://www.weiku.com/Farm-Machinery/buy-Napier-Grass-Chopper.html

Model TYZC-5

Power 5.5kw/8hp

Cutter rotating speed 800

Cutter no 3

Final Material Waft distance 1-5

Final size 10-30

Capacity Dry 0.2-0.8 Wet 2-4

Dimension 1.2*1.1*1.7

Weight 200

11
2.3.4 140HP tractor Napier grass shredder silage harvester machine

Figure 2.4: 140HP Napier grass cutter for commercial

https://www.alibaba.com/product-detail/Alibaba-malaysia-napier-grass-forage-

harvester

2.3.5 Overview

The design of parallel (double) discs header feeds all the crops uniformly into the

drum, which can cut all the stalks within the working width (not row by row), to

improve the yield rate. Besides that, it's adopted upright feeding roller, upright chaff

cutter, which is simple structure and stable performance, not only cutting off the straw

cuticle but also retaining the nutrients. Other than that, they are equipped with YTO

inline 4-cylinder with 140 hp turbo engine, efficient and high-powered. Furthermore,

The new cab with 270-degree wide field of vision and the simple operating system

makes it easy to drive. Talking about equipment, they came out with storage

12
containers of forage makes forages recycle and harvest more convenient. For the

track, this machine has big track, and short wheelbase makes it convenient and

flexible to bend and turn. Lastly, this Napier grass machine have high efficiency, low

price which only RM150.000 and low fuel consumption make this machine become

more and more small and middle size pasture’s first choice.

2.3.6 Specifications

Table 2.2: 140HP specification

https://www.alibaba.com/showroom/napier-forage-harvester.html

Item Unit Specification

Model
4QZ-1800

Overall dimension Mm 5200*1800*3300

Net weight Kg 5200

Engine power W 140

Main shaft speed of r/min 1300

cutting device

Rotor diameter of cutting Mm 800

device

Fragment length Mm Adjust the quantity of the

saws

13
 Walking velocity Km/h 1-10

Throwing drum turning

angle 270

Cutting device structure Upright

Header up-down scope Mm 0-400

Header width Mm 1800

Stubble height Mm <150

Figure 2.5: Double disc cutter

https://www.alibaba.com/product-detail/Alibaba-malaysia-napier-grass-forage-

harvester_60586626423.html

14
Cutting, feeding, smashing and throwing at one operation. Disc header design shortens

the length of the harvester and simple its structure. Compared with the reel harvester,

it is more efficiency and adaptability, decreased oil consumption and improved

reliability of the whole machine

Based on observation, most of the existing machines using specific systems to operate

the grass cutter machine. Among these are, belting system to actuating the gear which

is used for cutting process. Usually to spin the blade to cut and chop the grass. Other

than that, the existing machine used types of belting varied. Some using the Round

Belt, Vee Belt or Flat Belt. Through observation also, these machines use centrifugal

force to blow Napier grass that has been chopped into containers for feeding to

livestock.

2.5 BELTING

A belt is a loop of versatile material used to connect at least two turning shafts,

regularly parallel mechanically. Belts may be used as a wellspring of development, to

transmit control proficiently, or to track relative development. Belts are circled over

pulleys and may have a turn between the pulleys, and the poles require unparalleled.

For pulley framework, the belt can drive the pulleys regularly in one course (the same

if on parallel snails), or the belt might be crossed, so that the bearing of the determined

shaft is turned around (the other way to the driver if on parallel shafts). As a

wellspring of movement, a transport line is one application where the belt is adjusted

to convey a heap between two focuses consistently (Gupta, Dave, Gupta, & Dave,

2015)

15
2.5.1 TYPE OF BELTING

a) Round belts

Round belts are a roundabout cross segment belt intended to keep running in a pulley

with a 60-degree V-groove. Round depressions are reasonable for idler pulleys that

guide the belt, or when (delicate) O-ring sort belts are utilized. The V-groove

transmits torque through a wedging activity, accordingly expanding grating. In any

case, round belts are for use in generally low torque circumstances just and might be

bought in different lengths or slice to length and joined, either by a staple, a metallic

connector (on account of empty plastic), sticking or welding (on account of

polyurethane). Early sewing machines used a calfskin belt, joined either by a metal

staple or stuck, to extraordinary impact. (Peter Valdivia, 2013)

Figure 2.6: Round belt with several pulley

https://www.alibaba.com/product-detail/Mitsuboshi-polyurethane-conveyor-

belt-cord-Excellent_50005145298.html

16
b) Vee belts

Belt gearing with V-belts is peaceful, quiet and smooth operation. Its favourable

position is a probability to smooth sudden load changes and in addition damping of

vibrations. Straight forward and shoddy development (without body and oil) don't

require uncommon administration and exceptional upkeep what decrease expenses of

operation (Saputra & Wonoyudo, 2013).

Spent V-belts can be rapidly and efficiently traded without prolongation of machine

downtime. Belt gearings with V-belts offer probability to move a control at long

separations and additionally huge flexibility in the determination of hub base of

pulleys (Bdran, Saifullah, & Shuyuan, 2012). The apportion can be effortlessly

changed by utilization of pulleys with some depressions of various distances across

and by moving a belt from one notch to different ones.(Stomil Sanok, n.d.)

Figure 2.7: Vee belt usually use for mechanical engine

http://transpower.co.uk/belt-drives

17
c) Flat belt

Flat belts were used as a piece of the nineteenth and about twentieth many years in

line shafting to transmit control underway lines. They were moreover used as a piece

of multitudinous developing, mining, and logging applications, for instance,

bucksaws, sawmills, threshers, storage facility blowers, transports for filling corn

sanctums or horse shelters, balers, water pumps (for wells, mines, or swampy farm

fields), and electrical generators (Fan, Kraver, and Shah, 1996) . Level belts are as yet

used today, regardless of the way that not about as much as in the line shaft time. The

level belt is a fundamental course of action of compels transmission that was fitting

for its day. (Kumm and Kraver, 1987)

Figure 2.8: Flat belt in the engine

http://www.forbo.com/movement/en-gl/products/flat-belts/pjbman

It can convey high power at high speeds (500 hp at 10,000 ft/min), in instances of

wide belts and huge pulleys (Campbell, Mickelson, & Baumgartner, 1985). Be that as

it may, these drives are massive, requiring high strain prompting to high loads, and are

inadequately suited to close focuses applications, so V-belts have fundamentally

swapped level belts for short-separate power transmission, and longer-remove control

18
transmission is ordinarily no longer finished with belts by any stretch of the

imagination.

2.6 ADVANTAGES OF BELTING

The advantage of the belting framework is, the belt drives are straight forward and

conservative since they did not bother with a parallel shaft. Something else, belt drive

is outfitted with over-weight and stick insurance. For clamor furthermore, vibration is

completely damped out. Mechanical assembly life is developed the grounds that pile

instabilities are stagger ingested. Then, they are without oil and require less up keep

cost. For the effectiveness, belt drives are absolutely productive being used which is

(up to 98%, generally 95%). Finally, they are extremely conservative when the

separation between shafts is extensive. Other than that, the belt drive is easier to install

while absorbing minor misalignment.

19
2.7 CENTRIFUGAL FORCE

Overview

The definition of Centrifugal force is an invented compel, exceptional to a molecule

preceding onward a roundabout way that has similar measurements and greatness of

the drive that continually keeping the molecule on the roundabout way (the centripetal

drive) however focuses the other way. Many people confuse between centrifugal force

and centripetal force because they are nearly related. Centripetal force is

characterized as the segment of drive following up on the body in curvilinear

movement that is coordinated to the focal point of ebb and flow or hub of revolution.

Meanwhile, the definition of centrifugal force is the evident drive, equivalent and

inverse to the centripetal drive, drawing a turning body far from the centre of rotation,

caused by the inertia of the body.

Centrifugal force frequently happens when a surface's grating is deficient bring about

articles arranged on it to bring in tandem curvature with its curved movement. The

items still possess inertia; so instead, they may slide or fly in straight lines. This is

seen in numerous regular circumstances.

2.8 CONCLUSION

For this literature review, I have decided to come out with harvester machine

which focusing on the cutting and chopping.

20
 CHAPTER 3

METHODOLOGY

3.0 INTRODUCTION

The methodology has been used to make Napier Grass cutting machine. In this

chapter, a project flow chart is defined. The information related that included is

establishing target specification, basic drawing, and design. Analysis of design,

selection of components as per suitability selection of material, fabrication of

component, Assembly and testing. It also allows others to replicate my study and run

new and different studies that are based on our methodology

3.1 PROCESS FLOW

Table 3.1: Process phase

PHASE TITLE

Phase 1 Establish target

Phase 2 Basic drawing and design

Phase 3 analysis of design

Phase 4 Selection of components as per

suitability

Phase 5 Selection of material

Phase 6 Fabrication of components

Phase 7 Assembly and testing

21
3.2 FLOW CHART FOR FINAL YEAR PROJECT 1

Start

Identify the
problems

Solve the problems

Ideas generation
sketches

identify the
material

Technical drawing Detail design

\

FLOW CHART FOR FINAL YEAR PROJECT 2

Proceeds to
fabrication

No Yes
Testing Product
Accepted

End

22
3.3 PHASE 1

ESTABLISH TARGET SPECIFICATION

After the investigation of the objective, criteria selection will be developed. Criteria

selection here means the criteria that make this product more efficient. This product

already has in the market but certain criteria only. This is the criteria that I had to use

to design product for Napier grass cutter machine

• Easy to use

• Safety

• Heavy duty

• Low cost

3.4 PHASE 2

BASIC DRAWING AND DESIGN CONCEPT

The most purpose of this project is to design the double disc header feeds all the crops

uniformly into the drum, which can cut all the stalks within the working width to

improve the yield rate. The advantages of this project are to make cutting machine

without using many machine and reduce cost to done the Napier grass harvesting

process. So the new product and design should have a mechanism which make the

harvesting of the Napier grass more efficient and if farmer who use it, they could be

interested in this product because of the design and function much better than the

existing product. This is the idea concept for the new design of Napier grass cutting

machine.

23
CONCEPT EVALUATION

Evaluation is based on the concept pulleys and gear had been sketched. From these

sketches, an evaluation is made to evaluate the best concept or combine the concept.

The evaluation is based on existing product. Picture of the existed product is as below:

Figure 3.1: Worm gear concept to transfer the kinetic energy to move the

pulley

Figure 3.2: The main Double disc concept (cutting process)

24
3.5 PHASE 3

ANALYSIS OF DESIGN

3.5.1 Design Selection

After the process of sketching and evaluation, the selected design for Napier

grass cutter is as below

Figure 3.3: Double disc with cover sketching.

Figure 3.4: Double disc without cover.

25
3.5.2 Technical Drawing for Selected Design

For the selected design, technical drawing is produced through running out the

Autodesk Inventor software and has been rendered for the best performance

due the look of the design.

Figure 3.5: Perspective view

Figure 3.6: Right and Left view

26
 Figure 3.7: Plan View

3.5.3 Design Dimension

From the Autodesk Inventor Software, it generates the appropriate dimension for the

machine. This dimension will be used in producing real machine in the fabrication

workshop. The dimension can be seen below as per part that involve in this machine.

Final parts and final assembly is analysed by Inventor software.

Main double disc cutter

Figure 3.8: Double disc dimension

27
Frame

Figure 3.9: Cutter Frame dimension

Figure 3.10: Chopper Frame dimension

Figure 3.11: Plate bearing housing dimension

28
Cover

Figure 3.12: Cover dimension

Cutting Blade

Figure 3.13: 1st blade

29
 Figure 3.14: 2nd blade

Figure 3.15: 3rd blade

Figure 3.16: 4th blade

Figure 3.17: 5th blade

30
 Figure 3.18: 6th blade

Chopper

Figure 3.19: Chopper

3.6 PHASE 4

31
SELECTION OF COMPONENTS AND MATERIAL

After the design and analysis, the best design is studied to relate it with criteria

selection to make decision which components are suitable. For this project, as per

suitability of dimension according to the Napier grass cutting machine designed the

various parts which are the best after considering the criteria selection

After the analysis we specified the material of various components which use in this

cutting machine. For this project, it comes out with several parts that have to be

combined into the double disc header

Motor

Figure 3.20: Ac motor

32
Pulley

Figure 3.21: Groove pulley

Belting

Figure 3.22: Vee belt

Gear

Figure 3.23: Worm gear

33
Chopper

Figure 3.24: Chopper

Bearing

Figure 3.25: Bearing

34
Blade

Figure 3.26: Blades

Frame

Figure 3.27: Cutting and chopper frame

35
3.6.1 FUNCTION OF EACH PART

Table 3.2: Function of the part

PART FUNCTION

Engine To change the electric energy to kinetic energy and transfer it to

shaft and move the pulley to move chopper and cutter

Pulley A pulley is a wheel on an axle or shaft that is designed to support

movement and change of direction of a taut cable or belt along its
circumference. Pulleys are used in a variety of ways to lift loads,
apply forces, and to transmit power.

Belting The belt acts as a transmission belt. Connecting the belt pulleys, it
transmits the force from the engine to the ancillary components
including the alternator

Gear (worm Changing the route of the transmitting kinetic energy. From
vertical to horizontal movement
gear)

Chopper To chop into several silage sizes

36
Blade To cut the Napier grass from the land and transfer it to chopper

Frame To support all the component that involve in this machine

Bearing 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.

37
3.6.2 ESTIMATE COST

Table 3.3: Estimate cost

Part/Material Size Weight Quantity Price Per Total Price

Unit

Hollow Steel 40x40x2 14.45 Kg 1 RM 25.00 RM 25.00

mm x6m

Bearing 1-1/2" 1.900 Kg 19 RM 20.00 RM 380.00

Ucf208

Groove Pulley 23mm 900 G 2 RM 10.00 RM 20.00

Diameter

Groove Pulley 35mm 1 Kg 2 RM 15.00 RM 30.00

Diameter

Engine Sk42-
112m
1 RM 250.00 RM 250.00

38
 Belt 1 Meter 5 RM 2.50 RM 12.50

Total RM717.5.00

3.7 Redesigning the Design.

In fabrication on this project, there are several problems that need to be

concerned and the most suitable method that can be used to solve the problems

is by applying the Design for Manufacturing and Assembly (DFMA)

methodology. In identifying of Napier grass cutter machine problems, the most

important aspects that need to be concerned is the design of the grass cutting

machine. Some of the part grass cutting machines are being designed quite

complicated part and need to be eliminated, at the same time reducing the

manufacturing cost and assembly time. Besides that, there are several parts had

been recognized that difficult to handle. So, with the application of Design for

Manufacturing and Assembly (DFMA) methodology is highly expected in

solving these problems to suit the requirements and convenient for ruminant

feed dairy sector

New Design

3.7.1 Design Selection

After making new decision because of the several problems the selected

design for Napier grass cutter is as below

39
 Figure 3.28: Double disc with cover sketching.

Figure 3.29: Double disc without cover.

3.7.2 Technical Drawing for Selected Design

By using Autodesk Inventor software, the redesign and reducing part by part is

produce as technical drawing to get the actual 3d preference and dimension of

the Napier Grass cutter.

40
 Figure 3.30: Perspective view

Figure 3.31: Right and Left view

41
 Figure 3.32: Plan View

3.7.3 Design Dimension

The dimension of the new design that illustrate by using Autodesk Inventor

Software is what will be fabricate in the workshop. The Napier Grass Cutter is

using ratio 1:1 because the size of the machine is not quite big, suitable for

semi- commercial dairy farming in Malaysia and can complete the objective of

the research and development. The dimension can be seen below as per part

that involve in this machine.

42
43
 Figure 3.33: Design Dimension

3.8 PHASE 6

3.81 Selection Of Components And Material For Redesign

After the redesign and analysis, the best design is studied to relate it with

criteria selection to make decision which components are suitable. For this

project, as per suitability of dimension according to the Napier grass cutting

machine designed the various parts which are the best after considering the

criteria selection

After the analysis we specified the material of various components which use in

this grass cutting machine. For this project, it comes out with several parts that

have to be combined into the double disc header

44
Motor

Figure 3.34: Ac motor

Sprocket

Figure 3.35: Sprocket roller

Chain

Figure 3.36: Vee belt

45
Chopper Blade

Figure 3.37: Chopper

Bearing

Figure 3.38: Bearing

46
Blade

Figure 3.39: Blades

Frame

Figure 3.40: Cutting and chopper frame

47
3.8.1 FUNCTION OF EACH PART REDESIGN

Table 3.4: Function of redesign part

PART FUNCTION

Engine To change the electric energy to kinetic energy and transfer it to shaft

and move the pulley to move chopper and cutter

Roller Roller chain that transfers power from the Engine to the drive-wheel

Sprocket of the blade and chopper

Roller Chains are used to deliver positive power transmission in the forms of

Chain torque and speed ratio from one rotating shaft to another. Chains can

is used for rotate the double disc cutter and the chopper.

Chopper To chop into several silage sizes

Blade To cut the Napier grass from the land and transfer it to chopper

48
Frame To support all the component that involve in this machine

Bearing 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.

49
3.8.2 Cost after the Consideration

Table 3.5: Estimate cost of redesign product

Part/Material Size Weight Quantity Price Per Total Price

Unit

Hollow Steel 20ft 14.45 Kg 1 RM 85.00 RM 85.00

(Mild steel)

Bearing 1-1/2" 0.00049KG 5 RM 15.00 RM 75.00

Sprocket Gear 16T 900 G 5 RM 5 RM 25.00

Engine Sk42-
112m 1 RM 250.00 RM 250.00

Roller Chain 1 Meter 5 RM 15.00 RM 15.00

Total RM450

The different from the original planning about the design of Napier Grass cutter with the

new design is quite efficient and can reduce the cost of the fabrication. The original

planning cost is RM 717.50 was reduced by RM267.50 and total cost of the new design

is only RM 450

50
3.9 PHASE 7

Fabrication And Assembly

The harvester machine was fabricated by slightly altering the design for easier

manufacturability. Upon completion of fabrication, the model was tested for

workability. In this fabrication phase, there are only certain parts that show in this

phase because the purpose is just to show how the raw material was done in the

University workshop.

3.7.1 Details of component

The Napier grass cutter consists of two unit which is harvester unit and chopper unit.

Harvester unit consists of five types of blades and the chopper unit consist of sharp

spiral blade that can chop the Napier grass into the silage size that suitable to make the

ruminant feed.

The function of the harvester unit is to cut the Napier grass by using trimming action

of the blade and it is achieved by the sprocket gears that move by the kinetic energy

that produce by the motor. When the blade cut the Napier grass, the second blade now

working as a guide to push the Napier grass into chopper unit.

Most of the project’s parts were not fabricated in the University’s workshop. It was

however noted that some high precision parts such as the bearing, sprocket couldn’t be

machine or fabricate in the workshop. This is because it does already exist in market.

Mostly this Napier grass cutter using milling machine and lathe machine to fabricate

some parts for example the shaft.

The fabrications done by close assistance and supervision of the PPLV technician at the

workshop, whose invaluable help.

51
 3.9.2 Project planning

The following is a summary of the planning of the project, from its inception to

completion by using Grantt Chart method.

Table 3.6: Project planning table

Project Time taken to complete (in weeks)

stage
Final year project 1 Final year project 2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Research

Design

Material
survey
Fabrication
and assembly
Testing

documentation

In the initial stages of this project, 14 weeks that we have to complete the Final year

project 1 were used for research of the project. The researches include gathering

information from book, journals, that concluded at the reference page.

The second stage of the project was initialized one week later after the research of the

project was initialized. These stages conclude reviewing of existing design and

making preliminary sketches. From this review, it was decided that double disc design

is the most suitable for the Napier grass cutter machine. In addition, it was simple to

fabricate and its design could easily accommodate the cutting and chopping process

proposed.

52
The third stage which is last stages to complete the final year project 1 in this semester

was initialized at the week nine and it involved deciding what material to use from

what was readily available. During this same period, the design was taken for make

the cost estimating and request for funding made

3.9.3 Parts fabrication and assembly

In the beginning of the semester 2, the fabrication of the product has been started base

on the research and observation that have been made on the semester 1. The fabrication

of the Napier Grass cutter is quite complicated earlier on the starting point of the

fabrication, but after reducing certain part and making modification on the shape, the

flow of the fabrication become easier and not complicated as past.

The table below shows a brief description of the fabrication process for each part that

decide to do in university workshop

53
 Table 3.7: Fabrication of part

Parts No. Part name Fabrication process

involved

1 Body frame Cutting process using

grinder machine

2 Double disc cover Using aircon tank

54
3 Shaft Turning and drilling

4 Blade Laser cut

5 Bearing housing (Bush) Cut off from mild steel

hollow and weld to the
frame

55
 a) Framing

First of all, we design the body of model. For these purposes it will cut the hollow mild
steel in required dimension of shape of square

Length =30-inch
Width =21-inch

The frame is consisting of two section which is Harvesting section frame and
Chopping section frame. At the end of the fabrication, these two sections will be
combined to make easier to handle the machine

Harvesting Section

The frame is consisting of Square hollow mild steel. The length of frame is 600 mm
and width are 300 cm. the angle is heavy for the more load absorption. The first step is
cutting process on the straight 20ft hollow mild steel.

Figure 3.41: Frame

56
 b) Blades

Blades are used for cutting Napier grass by trimming mechanism. The blade which is

used for the actual for this project is made from Stainless steel, but for this prototype

are using only Aluminum as the it can reduce the fabrication cost for this project.

First of all, the mild still will be cut using shredding machine into square shape. Then

by using grinding machine, the shape of the real blade will be produce according to

the dimension and the real shape. One of the blade which is assume as the second

blade, will be needed to be bend at each the ends of the finger because its function is

to change the stand of the Napier grass after cutting process from vertical position into

horizontal position so that the Napier grass will be smoothly transferred into the

chopper unit.

The fabrication of each blade quite difficult because its need very accuracy while

working on it. For the first try, the shape of the blade is not according to the dimension

and shape plan. For the best performance, the blade has been fabricated by using laser

cut to keep the precise and accuracy in dimension and shape of the blade

Figure 3.42: All blades

57
 c) Top Cover

Cylinder housing is the main body for the cutter unit. Its produce from 230mm

diameter mild steel with height 200mm. Then, using grinder machine, the steel plate

was cut according to the design as shown below.

The entire seven blades will be attach on the cylinder shape which sized 300mm

radius to form a disc drum. Next, attaching the top cover to make the safety of the

machine much better. In the fabrication of this top cover, the main problem is to keep

the size is same each other. The round shape makes more complicated to fabricate

because its too big and the machine in the workshop is quite limited for the big round

material.

The process will repeat two times because the right and left disc is similar thing.

As what they called double disc header.

Figure 3.43: Double disc housing

58
 d) Chopper Section

Chopper section is the assembly that consist of the chopper with sharp blade that can

chop the Napier grass into the desire dimension of the silage. For this chopper it’s just

to cut the silage with size 1.5 cm only. Because it’s suitable to be as ruminant feed.

This roller is consisting with 1 Brush Cutter that size 12 inch. All of the parts in this

section are fabricate in the workshop and assemble according to the figure below:

Figure 3.44: Chopper frame

59
3.10 PHASE 6

ASSEMBLY

The body of the Napier grass cutter will assemble together with Frame, blade plates,

the top cover and the engine connector were connected to the shaft and bring it to the

several Roller sprockets. All the components are fixed their respective places.

The harvester unit consists of the following component.

Component:

a) Body:

The frame of a consist of following components suitably mounted:

1) Engine

2) Transmission system

3) Harvester assembly

4) Chopper assembly

Every each of the components recorded above is mounted in both of two ways, the

conventional construction, in which a different frame body is utilized and the frameless

or unitary development or construction in which no different casing is utilized. Out of

these, the customary kind of construction is being used by and by just for the substantial

vehicle though for auto the same has been supplanted by the frameless sort or the

monolog body is fabricating, which still find it economical to use the frame.

60
3.10.1Harvester assembly

The assembly of the harvester section is consisting of the frame, double disc cutter with

blades and the AC motor. First of all, we attach the blade to the shaft, the shaft is taken

from the 21mm dimeter hollow steel.

Figure 3.45: Shaft and Blade attachment

To put the blade in order of the arrangement illustrate in the Autodesk Inventor, we

make the key bush so that the blade can be raised and lowered according to the needs of

the user.

Figure 3.46: Key Bush

61
The key bush is made from aluminum and is made with CNC machine as it is easier to

fabricate with accuracy and save time the blade system can be used to modify the

working modifications and maintenance work as an example, even if one blade is

broken, can easily be switched.

Figure 3.47: Fabrication of bush using CNC machine

62
The key bush is attached to each blade by drilling holes on the blade and the bush.

Furthermore, using rivets, aluminum bush is mounted together with the blade

Figure 3.48: Bush attachment

Next, to install the shaft that consists of the blade, it uses two ball bearings to ensure that

the blade and shaft are not subject to tremors and violations between the two double

discs. Ball bearing is a component that plays an important role in preventing damage to

the blade and shaft.

Figure 3.49: Bush bearing

63
When the three elements are combined, they are placed in the body frame. By inserting

both the two bearing into the bearing bush located above and below the frame. The

purpose of the bush is to avoid defects while the bearing is working and preventing the

bearing of free movement.

Figure 3.50: Bearing inside the bush

Chopper Assembly

Assembly for section chopper, It includes frame, brush cutter, shaft and bearing and

sproket. This section of choping is a section to chop the napier grass after being cut by

the blade in the harvester section.

Figure 3.51: Chopper element

64
The first step is. Assemble a knife blade that is a brush cutter bought in a 12 inch-sized

market on a fabricated shaft using a lathe machine. Small but hard shafts can

accommodate the tension released during the power supply connection to the blade.

Initially a very strong vibration due to the rpm of the motor but after installing angle

iron as a shaft support, the shaking can be reduced.

Figure 3.52: Shaft supporter

When the blade and shaft are combined. The two components are mounted on a frame

made of mild steel. It uses MIG welding because it requires a good attachment to avoid

loosening. At the top of the frame is provided a plate of 1.6 mm thickness for a place for

ac motor.

65
 Figure 3.53: Engine’s plate

Transmision assembly

1. Transmision assembly on harvester section

Transmission assembly is something that makes this machine move and works. It

involves high component components of the mechanism such as the pulley, belting

an ac motor. But since this is a beta prototype, the part has been converted to

reduce the fabrication cost. The result of a neat discussion, ac motor cannot be

used because of the high speed cannot accommodate the unstable beta prototype

Figure 3.54: AC Motor

66
There are five sprokets used in this harvester section. The sprocket size used to move

the double-disc cutter is 16 teeth, the sprocket is one suitable component to replace the

pulley and replace the vee belt with the roller chain. The first step is to put a sprocket on

each shaft. The shaft is only used only one sprocket while the shaft is split right using

two sprockets. This is because the objective harvester section is cutting the grass in a

uniform and efficient manner. Both two blade shafts should rotate according to the

clockwise direction. The added purpose of the sprocket on the right side is to ensure the

movement towards the clock when the power is driven by the AC motor.

Figure 3.55: Transmissions of the gear

2. Transmissions assembly on the chopper section

Two sprockets are only needed to launch the current movement of the motor to the shaft

of the blade. The sprocket 16 of teeth are shunted at each shaft of motor and blade shaft.

Sprocket is attached by way of the welding process

67
 Figure 3.56: Transmissions of chopper

Engine

The real product actually using only one motor to generate power for two section which

is harvester section and the chopper. It is the model of SK42-112M of the mode helical

gear motor. It is the type of 2 stroke air cooled engine net power is 819 to 36 RPM (with

1750 RPM input)

Figure 3.57: Ac motor

68
The engine is the petrol plus kerosene. When it has started, it required gasoline means

beginning of the engine. Stop the petrol chock because we have required whole the

work with the help of kerosene through the work running on it so that the engine start.

The engine we can start with the help of starter the arrangement of starter by using the

rope which is attached to a rounded on the starter pulley which is mount motor shaft.

When the rope is pulled slightly, the engine will start at high speed up to the 3.6k rpm,

but we required only 900 rpm for a drive the chopper and the cutter multiple

applications of this engine because it can carry high speed so we can used cultivator,

absorber by using its speed.

There are two motors used in this project. One on the harvester section and one in the

chopper section. The right motor for the machine is about 1000 to 1500 rpm. This is

because the structure of the prototype is not suitable because the motor is too high for its

rpm.

Figure 3.58: Ac motors

69
The installation of the roller chain on each sprocket has been made to move every blade

available on this machine. Roller chain is the sort of chain drive most ordinarily utilized

for transmission of mechanical power on numerous sorts of the household. The purpose

of using the roller chain is to reduce the cost of making this machine.

Figure 3.59: Installation of the motor

70
3.11 Finishing

3.11.1 Finishing Process

Metal finishing is utilized to treat the outside of a metal item by applying a thin

correlative layer to its surface. There are various kinds of metal completing procedures

that can be utilized for an assortment of purposes. In this guide, we will survey the

significant finishing strategies and applications and contemplations for picking a metal

finishing the procedure. A portion of the general points of interest of applying this

finishing treatment to this Napier Grass Cutter:

• Increased durability

• Improved decorative appeal

• Enhanced electrical conductivity

• Potential for vulcanization

The finishing process performed on this machine is a process grinding and spraying the

colour for a static element. Surface pounding is used to convey a smooth finish on level

surfaces. It is a utilized grinding machining process in which a turning wheel shrouded

in unpleasant particles (grinding wheel) cuts chips of metallic or non-metallic substance

from a workpiece, scowling at it level or smooth.

71
 Figure 3.60: Grinding process

Spray painting is an artistic creation method where a gadget was coating a covering

through the air onto a surface. The most common types employ compressed gas usually

air to atomize and direct the paint particles. In this fabrication of the Napier grass cutter,

spray guns are having been using to spray the color coating. Spray guns evolved from

airbrushes, and the two are usually distinguished by their size and the size of the spray

pattern.

Figure 3.61: Spray painting process

72
3.11.2 Complete fabrication

After the all process were done. The all fabrication of the Napier Grass cutter for

ruminant feed is completed. Below is the picture of the complete machine.

Figure 3.62: Complete fabrication

73
 CHAPTER 4

FINDINGS AND DISCUSSION

4.1 Introduction

The following chapter concludes this report. A summary of the report is presented,

and findings of the study are discussed and interpreted. The significance of this

research in the immediate context of The Napier grass cutter for ruminant feed is

examined. Recommendations for further research at the end of the chapter.

The scope of the following Finding and discussion is limited to the context and the

fabrication of the Napier grass cutter for ruminant feed. Thus, applied to other

situations, these finding may yield incorrect assumptions. Still, these findings are

relevant to the process of harvesting in the progressive fabrication of Napier grass

cutter for ruminant feed projects.

The first topic to be discussed is the advantages of this machine. Many of the
advantages that can be made from this project and can answer all of the main
objectives of this report. The advantages can be noted below

• Ease of use

• Versatile and Durability

• Power and Convenience

• Safety Concern

74
Advantages of Napier Grass Cutter

4.1.1 Ease of Use

One of the biggest drawbacks of a Napier grass harvester is learning the cutting

techniques necessary to maintain a strategic distance from damage or harm to the

machine. The harvester has a specific cutting area, which means we cannot just hack

into Napier grass from any direction. The blades rotate clockwise, so we must straight

forward when cutting. The cutting zone is from in front and transfers the Napier grass to

the chopper section. If we hit a thick stem or branch with any other part of the blade, the

machine may kick back at you. Feed the blade into the brush or Napier grass slowly, so

the head is pressed against the material rather than swung at it. If we use a chopping

motion to cut with a brush cutter, the machine may smoke and stop working because

branches and other material may bind around the blades, causing it to overheat.

4.1.2 Versatility and Durability

Napier Grass cutter feature different blade attachments that allow you to cut a variety of

materials. They’re durable and reliable machines, as long as they receive proper

maintenance. However, the blade life depends on cutting and how often. For example, if

we are working frequently in rocky areas or cutting through hard stems or branches, we

may have to change or sharpen the blade daily. Before each use, we should check the

cutting-edge sharpness, since working with a dull edge abbreviates benefit life and can

represent a security risk.

75
 4.1.3 Power and Convenience

Napier grass cutter is powerful enough to cut through overgrown Napier grass that a

lawn mower or line trimmer cannot handle. They also cut in hard-to-reach areas where

larger machines cannot enter. However, most nippier grass cutter that already in the

market are cumbersome to operate, and if we have to clear a large area, fatigue can

occur. Most Napier grass cutter has a straight shaft and anti-vibration features to reduce

operator fatigue. Using a harness also helps control the machine and lightens the load as

you work.

4.1.4 Safety Concerns

Napier grass cutter is powerful tools that carry some risks if proper safety procedures

are not followed. We should never operate this machine without a harness, nor should

we use a Napier grass cutter that is not equipped with a handlebar. The handlebar is

what helps we control the machine. Furthermore, it additionally fills in as a boundary to

counteract damage should the machine be thumped out of our hands. Always wear eye

protection when using this machine, because the blade can throw debris back at us.

76
 CHAPTER 5

CONCLUSTION

Our project entitled design and development of Napier grass cutter for ruminant feed are

effectively completed and the results obtained are satisfactory. It will be easier for the

people who would go to take the project for the further modifications. We are

effectively completed manually and also engine driven previously A grass cutter.

Concerning illustration, we need remotely worked framework is also actualized

expected safer and simple for those working. And the winding sharpened steel provides

for the cutting and the gathering of grass cutter will be carried out effortlessly. This

Napier grass cutter is light weight what’s more space will be involved.

This Napier Grass cutter for ruminant feed will meet the challenge of environmental

production and low cost of operation since there is made especially for semi-

commercial dairy farming. Napier Grass cutter has been developed for the use of dairy

farmer and establishments for small dairy farming the in other word is created for semi-

commercial. The machine's ability is sufficient for its motivation. The machine has

proved to be a possible replacement for the manual handling and can reduce the

harvesting duration.

77
REFERENCES

Aaqib Gulzar Khan1, Adeel-ul-Haq Qurishi. (n.d.). Commercial Grass Cutting cum

Collecting Machine. 1 NOV 2013.

Bdran, S., Saifullah, S., & Shuyuan, M. (2012). An overview on control concepts of

Push-Belt CVT. International Journal of Engineering and Technology, 4(4),

392.

Campbell, C. R., Mickelson, E. S., & Baumgartner, S. A. (1985). Method for fabricating

non-linear side wall conveyor belting.

Cook, T. F., & McGhee Jr, D. H. (1994). Grass chopper.

Gupta, D., Dave, D., Gupta, D., & Dave, D. (2015). Study and performance of Belt

Conveyor system with different type parameter. International Journal, 2, 29–

31.

Orodho, A. (2006). The role and importance of Napier grass in the smallholder dairy

industry in Kenya. Food and Agriculture Organization, Rome) Retrieved

August, 24, 2011.

Peter Valdivia. (2013). Round Belt Pulleys Information. Retrieved from

http://www.globalspec.com/learnmore/motion_controls/power_transmission_

mechanical/round_belt_pulleys

Saputra, A. H., & Wonoyudo, B. D. (2013). Pola Vibrasi Dari Transmisi V-Belt

Dibawah Pengaruh Parallel Misalignment. Jurnal Teknik ITS, 2(2), F239–

F242.

Stomil Sanok, S. . (n.d.). Advantages of gearings with V-belts. Retrieved from

http://www.harvestbelts.biz/en/handbook/advantages-of-gearings-with-v-belts/

Vieira, R. A., Pereira, J., Malafaia, P. A., & de Queiroz, A. C. (1997). The influence of

elephant-grass (Pennisetum purpureum Schum., Mineiro variety) growth on

78
 the nutrient kinetics in the rumen. Animal Feed Science and Technology, 67(2–

3), 151–161.

Wong, M. J., Rajion, M. A., Leong, Z. P., Ebrahimi, M., & Goh, Y. M. (2012). In vitro

evaluation of Napier grass-oil palm frond combination as ruminant feed.

79
80