Debre Tabor University Faculty of Technology Department of Mechanical Engineering Project On: - Design and Fabrication of Hand Operated Maize Sheller

DEBRE TABOR UNIVERSITY
FACULTY OF TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
Project on: - Design and fabrication of Hand Operated Maize Sheller
Prepared by:
Name ID NO
1. Endaylalu Eyaye 1326/07

2. Berhan Asnakew 1119/07
3. Bekalu Mulu 1368/07
4. Mulugeta Asnakew 0951/07
5. Yibeltal Hunegnaw 1165/07
Advisor: Mr. Yusuf A.(Msc)
SUBMITION DATE 15/10/2011 EC
DEBRE TABOR, ETHIOPIA

DESIGN AND FABRICATION OF MAIZE SHELLER 2011 E.C
DECLARATION
We hereby declare that the project paper titled ―design and fabrication of maize Sheller
machine‖ submitted by us is based on actual and original work carried out by us. Any reference
to work done by any other person or institution or any material obtained from other sources have
been duly cited and referenced. We further certify that the project paper has not been published
or submitted for publication anywhere else nor it will be send for publication in the future.
Advisor name Examiner name
Mr Yusuf A.
…………………………… ………………………..
Signature Signature
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ACKNOWLEDGMENT
We would like to acknowledge our advisor MR. YUSUF ALI for his continuous
encouragement, valuable advice, guidance, support and helping during in most of design
activities. To do this final project from initial up to last. For his grateful assistance and advice
that brings the project to success. For more, we would like to thank our mechanical department
for to giving the permission to do our project work with laboratory or workshop and other
necessary thing. Finally, we would like to thank a person who helps us during our project works
and also our friends to support us by encouragement and giving some necessary information.
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ABSTRACT
As we know the maize shelling mechanism in Ethiopia mostly in rural area have done in
traditional ways by using, human thumb, animal’s wooden bloke etc. But this mechanism is
much tedious, time consuming and also less efficient productions due to this reason we initiate to
develop manual operated maize Sheller machine. This machine is used to solve the above
problems and its uniqueness is no need of electric power, so can easily use in rural area. It works
by combination of parts mesh each other, apply human hand force on handle and transmits some
rotational motion to the shaft by using pulley and belt, and then this rotation motion translate to
the second shaft (vertical) in some ratio of bevel gears. Threshers fixed with rotational shaft then
during this mechanism can simply thresh maize grain from cob. This machine is capable of
reducing the total capital cost, increase productivity, to be easily portable and reduce time
consuming. The main objective of this project is to help our rural people concerning to the maize
grain shelled by using our mechanical knowledge with the appropriate use of materials that used
for less manufacturing cost relative with their advantageous. Have High production capacity up
to 250kg ⁄hr. Low vibration and easy to move finally, this machine can be easily distributed for
rural areas of the country.
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TABLE OF CONTENTS
DECLARATION ........................................................................................................................................... i
ACKNOWLEDGMENT............................................................................................................................... ii
ABSTRACT................................................................................................................................................. iii
LIST OF FIGURE...................................................................................................................................... viii
LIST OF SYMBOL ..................................................................................................................................... ix
CHAPTER ONE ........................................................................................................................................... 1
1 INTRODUCTION ..................................................................................................................................... 1
1.1 Problem Statement ............................................................................................................................. 3
1.2 Objectives............................................................................................................................................ 4
1.2.1 General Objective ........................................................................................................................ 4
1.2.2 Specific Objectives ...................................................................................................................... 4
1.3 Scope of the project ............................................................................................................................ 4
1.4 Significance of this project .................................................................................................................. 5
1.5 Limitation of the project ..................................................................................................................... 5
CHAPTER TWO .......................................................................................................................................... 6
2 LITERATURE REVIEW .......................................................................................................................... 6
2.1 Physical and Mechanical Properties of Maize .................................................................................... 6
2.2 Maize shelling techniques ................................................................................................................... 6
2.2.1 Hand shelling ............................................................................................................................... 7
2.2.2 Maize-shelling with Rotary Equipment. ...................................................................................... 7
2.2.3 Mechanized shelling or shelling with motorized equipment ....................................................... 8
2.3 Past literature and researches ............................................................................................................ 9
2.4 Summarize literature review ............................................................................................................ 12
2.5 CONCEPT DEVELOPMENTS AND MODELING .................................................................................... 13
2.5.1 Concept Developments .............................................................................................................. 13
CHAPTER THREE .................................................................................................................................... 20
3 METHODOLOGIES AND MATERIAL SELECTION ......................................................................... 20
3.1 Methodology..................................................................................................................................... 20
3.2 Material selection ............................................................................................................................. 21
3.2.1 Material selection for shaft, Sheller, and hopper ....................................................................... 23
3.2.2 Bevel gear Material selection ..................................................................................................... 23
3.2.3 Material for Plummer block or bearing...................................................................................... 24
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3.2.4 Material for v belt ...................................................................................................................... 25

3.2.5 Material for v belt drive or pulley and handle............................................................................ 26
3.2.6 Frame structure .......................................................................................................................... 26
CHAPTER FOUR....................................................................................................................................... 28
4 DESIGN ANALYSES ............................................................................................................................. 28
4.1 Part Description ................................................................................................................................ 28
4.2 Design Considerations....................................................................................................................... 28
4.3 Geometric Analysis ........................................................................................................................... 29
4.3.1 Handle Design ............................................................................................................................ 29
4.3.2 Pulley geometric analysis........................................................................................................... 30
4.3.3 Design of Bevel Gear ................................................................................................................. 33
4.3.4 Design of thresher or Sheller ..................................................................................................... 36
4.3.5 Design of hopper ........................................................................................................................ 37
4.3.6 The Main Frame ......................................................................................................................... 41
4.4 Force analysis .................................................................................................................................... 43
4.4.1 Hand crank ................................................................................................................................. 43
4.4.2 Pulley force analysis and v-belt selection .................................................................................. 44
4.4.3 Bevel Gear Force Analysis ........................................................................................................ 45
4.4.4 Bevel Gear stress analysis .......................................................................................................... 48
4.4.6 Thresher or Sheller force analysis .............................................................................................. 57
4.5 Design of shaft .................................................................................................................................. 58
4.5.1 Shaft one (Shelling shaft) ........................................................................................................... 59
4.5.2 Shaft two (transmission shaft).................................................................................................... 67
4.6 Design of key ..................................................................................................................................... 77
4.6.1 Design of square key .................................................................................................................. 77
4.6.2 Design of key way...................................................................................................................... 79
4.7 Bearing Selection .............................................................................................................................. 79
4.8 Manufacturing process ..................................................................................................................... 84
4.9. Maintenance and Lubrication .......................................................................................................... 85
4.10 working principle ............................................................................................................................ 87
CHAPTER FIVE ........................................................................................................................................ 88
5. RESULT AND DISCUSSION ............................................................................................................... 88
5.1. Result ............................................................................................................................................... 88
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5.2. Cost analysis ..................................................................................................................................... 89

CHAPTER 6 ............................................................................................................................................... 90
6. CONCLUSION AND RECOMMENDATION ...................................................................................... 90
6.1 Conclusion ......................................................................................................................................... 90
6.2 Recommendation.............................................................................................................................. 91
REFERENCE.............................................................................................................................................. 92
APPENDIX ................................................................................................................................................. 94
Part drawing ............................................................................................................................................ 94
Assembly drawing ................................................................................................................................. 109
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LIST OF TABLE
Table 2-1 Concept development criteria ..................................................................................................... 16

Table 2-2 Decision metrics for selecting conceptual design ....................................................................... 18
Table 3-1 Evaluation material selecting for shaft, Sheller and hopper ...................................................... 23
Table 3-2 Evaluation of material selection for bevel gear .......................................................................... 24
Table 3-3 Evaluation material selection for bearing ................................................................................... 25
Table 3-4 Evaluation material selection for v belt ...................................................................................... 25
Table 3-5 Evaluation material selection for pulley and handle.................................................................. 26
Table 3-6 Shows the parts of the machine as well as the material selected for each part. .......................... 27
Table 4-1 Dimensions of standard v belt according to IS, 2494 – 1974. .................................................... 30
Table 4-2 To calculate KA over load factor is from this table, source ANSI/AGMA 2003 B97 ................ 49
Table 4-3Table Allowable Contact Stress Number for Iron Gears, sac ( ) Source: ANSI/AGMA
2003-B97. ................................................................................................................................................... 52
Table 4-4 Bending stress (allowable) ............................................................................................. 56
Table 4-5 Results of force measurements averages. ................................................................................... 57
Table 4-6 The following table shows the recommended values for Km and Kt. ............................................
Table 4-7 To calculate dynamic equivalent ............................................................................................... 81
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LIST OF FIGURE
Figure 1-1 Shelling with hand....................................................................................................................... 3
Figure 2-1 Antique maize Sheller’s .............................................................................................................. 8
Figure 2-2 motorized maize Sheller .............................................................................................................. 9
Figure 2-3 Hand held maize Sheller ............................................................................................................. 9
Figure 2-4 Manually inserted and rotated against the shelling unit which is threaded bolt assembly. ....... 10
Figure 4-1 handle free body diagrams ........................................................................................................ 29
Figure 4-2 pulley free body diagram........................................................................................................... 31
Figure 4-3 Terminology of bevel gears....................................................................................................... 33
Figure 4-4 thresher ...................................................................................................................................... 36
Figure 4-5 Hooper ....................................................................................................................................... 37
Figure 4-6 maize cob with grain ................................................................................................................. 39
Figure 4-7 Frame or supporter .................................................................................................................... 42
Figure 4-8 pulley free body diagram........................................................................................................... 44
Figure 4-9 Bevel-gear tooth forces. ............................................................................................................ 46
Figure 4-10 Contact geometry factor ZI ...................................................................................................... 51
Figure 4-11 Bending Strength Geometry Factor (YJ) ................................................................................. 55
Figure 4-12 Free body diagram................................................................................................................... 59
Figure 4-13 Free body diagram................................................................................................................... 60
Figure 4-14 Bending moment diagram for x axis ....................................................................................... 63
Figure 4-15 Bending moment diagram for z axis ....................................................................................... 64
Figure 4-16 free body diagram.................................................................................................................... 68
Figure 4-17 force free body diagram .......................................................................................................... 69
Figure 4-18 bending moment diagram ........................................................................................................ 71
Figure 4-19 bending moment diagram for ................................................................................................. 74
Figure 4-20 key free body diagram ............................................................................................................. 77
Figure 4-21 geometry for bearing ............................................................................................................... 84
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LIST OF SYMBOL
Symbol Name Unit
V Volume m3
M Mass kg
g Gravity m/s2
W Weight N
N Speed rpm
D Diameter m
ρ Density kg/m3
Angular Velocity rad/s
Z Number of Teeth -
R Radius m
B Width m
ha Addendum m
hd Dedendum m
h Height m
a Base of Teeth Triangle m
c Height of Teeth Triangle m
l Length m
Ncob Number of Cob with Grain -
σ Stress N/m2
F Force N
A Area m2
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FS Factor of Safety -
E Elastic Modules N/m2
σult Ultimate Tensile Stress N/m2
σy Yield Stress N/m2
P Power W
T Torque Nm
Μ Coefficient of Friction -
θ Angle rad
Wt Tangential Force N
Wr Radial Force N
Wa Axial Force N
β Pressure Angle rad
γ Reference Cone Angle rad
σH Gear Contact Stress N/m2
ZE Elastic Coefficient (N/mm2)1/2
Zi Pitting Resistance Geometry Factor -
Zxc Crowing Factor for Pitting Resistance -
KA Over Load Factor -
KV Dynamic Factor -
KHB Load Distribute Factor -
Zx Size Factor for Pitting Resistance -
u Poisson’s Ratio -
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σHP Permissible Bending Stress N/m2
σHlim Allowable Contact Stress N/m2
ZNT Stress Cycle Factor for Pitting Resistance -
Zw Hardness Ratio Factor -
SH Contact Factor of Safety -
Kθ Temperature Factor -
Zz Reliability Factor for Pitting -
Yx Size Factor for Bending Strength -
met Outer Transferred Module m
Yβ Length Wise Curvature Factor for Bending -
Yl Geometric Factor for Bending Stress -
YNT Stress Cycle Factor for Bending Strength -
Yz Reliable Factor for Bending Strength -
q Production Capacity kg/s
M Momentum Nm
Shear Stress N/m2
C Basic Dynamic Load Rating N
Km Combined Shock and Fatigue Factor -
KA Radial Load Factor -
KB Axial Load Factor -
YJ Geometric Factor for Bending -
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CHAPTER ONE
1 INTRODUCTION
Maize is the most important cereal grain in the world, after wheat and rice, Maize said to
have originated in tropical zones of America is the third most important cereal crop in the world,
next to wheat and rice. World maize production is estimated 856 million tons in 2011/2012
Ashwin and Shaik, (2014). Maize contains starch (60%-88.0%), protein (8.8%-12%), fat (3%-
5%) and minerals (1%-5%), providing nutrients for humans and animals and serving as a basic
raw material for the production of starch, oil and protein, alcoholic beverages, food sweeteners
and, more recently, fuel. In Ethiopia, maize grows from moisture stress to high rainfall areas and
from lowlands to the highlands. It is one of the most important cereal crops grown in the country
and is the main staple food in rural areas. It accounts over 14% and 18% in terms of land area
coverage and productivity respectively with higher annual growth rate. Ethiopia is the largest
maize producer in Eastern and Southern Africa. Over 8 small holder farmers are engaged in
maize production and this accounts 28% the total cereal production. The total maize production
in 2010/2011 was estimated 4.98 million tons (Demeke et al.2). The overall productivity of
maize is affected by many factors including lack of post-harvest technologies, such as shelling.
Maize kernels should be removed from cob to be used as seeds, prepare value addition, improve
handling and storage as well as maintain its quality.
Maize shelling involves detaching of the maize grain from its cobs. Maize shelling is
among the major activities involved in the processing of maize like harvesting, drying, de-
husking, storing, and milling. All these processes are costly and for the rural farmers to
maximize profits on their produce, appropriate technology suiting their needs must be used.
Maize shelling is a necessary process subsequent to harvesting because the maize kernels when
harvested are firmly attached to the hard cob. Shelling which refers removal of kernel from cob
is an important post-harvest operation in maize production. Shelling can be carried out in the
field or on the farm. Maize shelling is difficult at moisture content above 25%, with this moisture
content, grain stripping efficiency is very poor with high operational energy and causing
mechanical damage to the seed. A more efficient shelling is achieved when the grain has been
suitably dry to 13 to 14% moisture content (Danilo et al.3).
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Maize shelling in Ethiopia is mainly carried out using traditional methods, the most
commonly employed methods include manual rubbing maize cobs against one another, using
human finger, biting the cob with wooden plank, treading with animal. Likewise, the grain can
be detached from the cob with the use of pestle and mortal. All these traditional maize shelling
methods are highly tedious, inefficient; do not support large-scale shelling of maize requiring a
lot of labor and time with low productivity as a worker can only shell a few kilograms per hour.4
Kernel damages in the form of bruiser, crack or breakage are inevitable during these shelling
methods. Such kernel damage facilitates the infestation of field pests during storage. Attempts
were in the past to develop and introduce engine driven and tractor driven high capacity
Sheller’s. The technology though perfect is not within the reach of marginal farmers. Existing
motorized Sheller are too expensive to be purchased by resource poor smallholder farmers. The
cost of hiring to get the service is even high for most farmers. Bahir Dar Agricultural
Mechanization and Food Science Research Center has adapted cylindrical hand operated and
motorized maize Sheller’s and preliminary demonstration reveals that farmers have shown
interest to use them. Thus, there is a need to introduce this implement that reduces post-harvest
loss, increase labor efficiency in time and avoid the drudgery and harms to the hand of men and
women farmers. Thus, there was a need to demonstrate both of the machines and collect
feedback from farmers that are useful for future promotion and modification activities. This was
supported by the national strategy that states further strengthening the introduction of suitable
post-harvest tools.
Maize production in Ethiopia is a great importance with the increase in population and
use of maize grain, the market demand for maize grain also increased. However, maize shelling
in developing and under-developed nations has been and remains a serious problem to its
processing as it is tedious and often require considerable labor hours.
In industrialized countries, maize is largely used as livestock feeds and as raw material for
industrial products, while in low income countries; it is mainly used for human consumption.
Maize is an important source of carbohydrate, protein, iron, vitamin B and minerals. In Africa,
maize is consumed as a starchy base in wide variety of porridges and pastes. Green maize (fresh
on the cob) is eaten parched, baked, roasted or boiled which play an important role in filling the
huge gap after dry season.

1.1 Problem Statement

In Ethiopia the most commonly employed methods for maize shelling include manual
rubbing maize cobs against one another, using human finger, biting the cob with wooden plank,
treading with animal. Likewise, the grain can be detached from the cob with the use of pestle and
mortal. All these traditional maize shelling methods are highly tedious, inefficient; do not
support large-scale shelling of maize requiring a lot of labor and time with low productivity as a
worker can only shell a few kilograms per hour for Kernel damages in the form of bruiser, crack
or breakage are inevitable during these shelling methods.
Shelling of the dried cobs by majority of farmers (about 96%) in the study area is carried
out by repeated beating of the cobs with a club while held inside Sacks, open barrels or spreading
it over plastered ground floor in the house or outdoor. This method cause damage to the kernels
or ox and are time consuming involving drudgery. Other traditional maize shelling technique is
rubbing the maize cobs against one another by hand or by direct removal of kernels pressing it
between thumb and hand palm.
 Removing the grain from the cob has been a time consuming and tedious process for the
rural maize farmer.
 Traditional shelling methods do not support large-scale shelling of maize.
 Existing motorized Sheller’s cause great damage to the maize seeds besides breaking the
cob to pieces and are costly to hire or purchase
 There is need therefore to develop a maize threshing technique to meet the shelling needs
of such farmers.
Figure 1-1 Shelling with hand

1.2 Objectives
1.2.1 General Objective
The general objective of this project is to design and fabrication of hand operated maize
Sheller machine.
1.2.2 Specific Objectives

 Review existing maize shelling techniques in our county (Ethiopia).
 Design a hand operated maize Sheller components such as Frame, Sheller,
Hopper, Handle, Rotor shaft, bevel gear, Outlet for removing kernel of maize s.
 Modeling part and assembly drawing
 Manufacture parts of this machine
 Assemble hand operated maize Sheller
 Test the product
1.3 Scope of the project

The scope of this project is to design and fabrication of hand operated maize Sheller up to
test. This maize Sheller is to be manually operated equipment. Its work output will depend on the
operator(s) as well as on the machine itself. This design focuses on energy considerations to
improve man-machine system efficiency. The energy parameters analyzed are geometric Force,
Torque and Power requirements in operating the machine.

1.4 Significance of this project

In our country (Ethiopia) Maize is shelled traditionally by free hands. But this traditional
method of shelling is highly tedious, inefficient and time consuming with low productivity as
worker can only shell a few kilograms per hour so that the significance of this project to assess
and decrease the problems of the previous maize Sheller. The power operated maize Sheller
machine requires electrical energy for its working and its capital investment is also high
compared to the conventional methods of shelling but in rural areas supply of electricity is not
good at all times. Hence there was a need for an innovative idea or product that is feasible, safe,
cost effective and productive for the Ethiopian farmer. So in order to suit the prevailing condition
and reduce the capital investment and operating costs, hand operated maize Sheller needs to be
developed.
1.5 Limitation of the project

The limitation of this project in the part bottom of hopper, when the input is large
diameter of maize and then the grains are shelled due to sheller force. At that time some part of
miaze cob is removed with grain because the hopper outlet is designed by considering the
smalest diameter of the maize cob with grain.

CHAPTER TWO
2 LITERATURE REVIEW
This chapter includes summary of the past literature and researches which are relevant to
the present study. The literature associated with various aspects of the present study is divided
under the following sub heads as
 Physical and Mechanical Properties of Maize

 Maize shelling techniques
 Past literature and researches
2.1 Physical and Mechanical Properties of Maize
It is well known that physical and mechanical properties of grains are essential for the
design of machines used for various operations such as seeding, planting, harvesting, threshing,
processing and storage. Many researchers have studied the physical and mechanical properties of
food grains, pulses, oilseeds and other crops and determined the interaction between various
parameters. Standard methods and procedures have been adopted for this purpose.
The physical and rheological properties of grain are studied in order to predict the
reaction of seed to actual handling circumstances. They reported that moisture content had
greatest influence on the mechanical properties of grain. All strength properties decreased in
magnitude as moisture increased. At high moisture content more energy was required to rupture
grain kernels by impact-shear than static-shear. Elastic properties were present at low and plastic
properties at high moisture contents. This research used as a reference to study the maize Sheller.
[23]
2.2 Maize shelling techniques

Depending on the influence of agronomic, economic and social factors, shelling is done
in different ways:
 Shelling by hand, with simple tools

 Mechanical shelling with simple machines operated manually
 Mechanical shelling with motorized equipment

2.2.1 Hand shelling

The easiest traditional system for shelling maize is to press the thumbs on the grains in
order to detach them from the ears. Another simple and common shelling method is to rub two
ears of maize against each other. These methods however require a lot of labor. It is calculated
that a worker can hand-shell only a few kilograms an hour Shelling of maize as well as of
sunflowers, can be more efficiently accomplished by striking a bag full of ears or heads with a
stick. Maize and sunflowers can also be shelled by rubbing the ears or heads on a rough surface.
Small tools, often made by local artisans, are sometimes used to hand-shell maize. With these
tools, a worker can shell 8 to 15 kg of maize an hour. [13]
The simplest type of maize Sheller is a circular handheld device made of cast iron or cast
aluminum, with new models retailing for under Ksh.1500. To use this type of Sheller, the
operator holds and rotates the Sheller in one hand while pushing the cob of corn through the
teeth of the machine. This type of Sheller is best suited for occasional use by maize growers
requiring the seed or kernel samples for moisture and disease testing. This simple Sheller’s can
also be used by home gardeners who want to shell a few dried maize cobs for use as chicken
feed. Since using a handheld Sheller is slow and labor intensive, this model is not suitable for
processing multiple cobs of corn at once. [13]
2.2.2 Maize-shelling with Rotary Equipment.

Manual Sheller’s, which are relatively common and sometimes made by local artisans,
permit easier and faster shelling of ears of maize. These come in several models, some of them
equipped to take a motor; they are generally driven by a handle or a pedal. Use of manual
Sheller’s generally requires only one worker. A good example is the Antique maize Sheller’s.
The major setbacks with these Sheller’s are that their shelling capacities are low and its shelling
is unit or one to one, and most of them require to be fixed on benches before operation. Also
their method of operation is too cumbersome from the fact that the crank handle is directly
connected to the shelling chamber and therefore the effect of friction is too vigorous during the
shelling operational. [22]
The most common type of mechanical maize Sheller in the market today is a rotary
Sheller which can shell up to six cobs of corn per minute translating to approximately 50kg/hr. A

new such Sheller made of cast-iron can be purchased for less than Ksh. 8500 at farm and garden
supply stores. However, Antique maize Sheller’s (grinder pitter tool - "never fail" Plymouth root
heath corn Sheller’s) are often available in the market and are the preferred type of rotary maize
Sheller’s each at a sale price of Ksh. 10700.
Most mechanical corn Sheller’s that are produced and sold today are constructed of cast
iron with a hand crank. These machines are usually designed to be either mounted on a
workbench or suspended between two supports over a bucket where the kernels are collected.
This on its own presents a setback for their use as most farmers do not have much time and
energy to mount and unmounts the equipment every time they need to shell their produce.
Furthermore, the output capacity of this Sheller is relatively low for the rural farmers
harvesting more than 20 sacks of maize and this would require them to spend quite some time in
extends of hours or days to complete the entire threshing process.[22]
Figure 2-1 Antique maize Sheller’s. [22]
2.2.3 Mechanized shelling or shelling with motorized equipment

Now a days many small maize Sheller’s, equipped with a rotating cylinder of the peg or
bar type, are available on the market. Their output ranges between 500 and 2000 kg per hour, and
they may be driven from a tractor power take off or have their own engine; power requirements
vary between 5 and 15 hp according to the equipment involved. This motorized maize Sheller is
designed, but in Ethiopia it is not good for rural area because of the shortage of electric power.
[22]

Figure 2-2 motorized maize Sheller. [22]
2.3 Past literature and researches
Evaluation and demonstration of maize Sheller’s for small-scale farmers, in this research
hand held maize Sheller is a light, simply constructed, and inexpensive maize Sheller made from
steel tubes with shelling teeth fixed internally. With this Sheller, maize cob held on one hand is
rotated against a stationary shelling device held on the other hand, or vice versa. In the process,
the teeth of the Sheller entangle and remove the grain from the cob. It eliminates the usual pain
experienced when shelling by hand. Shelling maize is becoming a laborious task for hybrid
maize producers mainly when seasonal labor shortage is at peak. In order to reduce drudgery in
small scale shelling, a comparative test was conducted between traditional and simple hand held
maize. [6]
But the disadvantage of this mechanism is it has low shelling efficiency because when
the small size maize is feed in to the cylinder then it passes directly without shelling.
Figure 2-3 Hand held maize Sheller. [6]

Modification and testing of Jimma adjustable hand maize Sheller research in Jimma
Ethiopia The shelling unit shells out the kernels from the maize cob when the cob is manually
inserted and rotated against the shelling unit which is threaded bolt assembly. [9]
But this is low efficiency for maize shelling, shelling capacity is low or unit shelling and
also it is dangerous or tedious to work.
Figure 2-4 Manually inserted and rotated against the shelling unit which is threaded bolt
assembly. [9]
The de husking and shelling are important post-harvest activities in maize crop,
predominantly done by women. These activities involve a lot of drudgery as these are done
manually. The maize shelling with the tool makes women's lives difficult and yields very low
level of output. Moreover, de husking as a separate activity precedes shelling that brings
additional burden on farmers. The farmers or field owners find it difficult to afford the machines.
The machine is operated by 1 person and requires feeding of cobs one by one. But its limitation
is low shelling efficiency because the maize is shelled one by one. In order to make it affordable
and more convenient to shell the maize, and as a part of our academic project, we have
developed a ―hand operated maize Sheller‖ using ergonomic and mechanical considerations for
and shelling. It consists of hopper with internal thread from where the maize is inserted. The
handle is connected to the pulley. When the pulley is rotated, the gear rotates and shells the
maize by Sheller. [12]
There are many maize shelling techniques in India which are used in our life. The main
problems with these machines are that they are not affordable to farmers who are having acreage
farms and which they do not require these big shelling machines. Many farmers in Ethiopia are

not affordable to use these machines because of their cost. So these farmers resort hand operated
tools which gives low output, more damages of kernel threshed from cob, which is monotonous
work. Since inventions of maize shelling by machines reduced the hectic work for farmers. But
these machines never provided the cost saving, accident precautions. These machines are
automatic operated, fuel operated. So as man machine system can be established these machine
provides simple mechanical design. This literature report is review on human powered machine,
the survey proved to system which shows cost effective and functional viable. [13]
The hand operated maize dehusker-sheller was ergonomically evaluated with ten farm
women to assess the physiological workload and its performance in standing and sitting postures.
Two workers are required during its operation, i.e., one for hand cranking and another for
feeding the cob. One by one cob (without removing its outer layer/sheath) was fed in hopper at
an interval of about 4 s. The limitation of this project is it needs two persons or workers but in
our project we reduce man power it needs one worker. [14]
Operating speed of rotary maize Sheller was optimized for its operation at higher
operating speeds in pedaling mode, by conducting a simulation study for three sizes of maize
cobs at seven operating speeds. The shelling capacity and shelling efficiency of maize Sheller for
all categories of maize cobs increased curvilinear with increased in operating speed up to about
70 r.p.m. The shelling capacity at a particular operating speed decreased with increased in the
maximum diameter of cobs. Operating torque of rotary maize Sheller for a given size of maize
cobs decreased with increased in operating speed. On the other hand, the torque decreased with
decreased in maximum diameter of maize cobs at a given operating speed. It was concluded that
the operating speed of maize Sheller should be 70 to 80 r.p.m. for higher shelling capacity,
shelling efficiency and lower operating torque. [15]
To developed such a machine and suggest the farmers to adopt suitable values of crop
and machine operational parameters for the optimum threshing. The studies were carried out in
three different phases. In the first phase, physical properties of maize kernel and maize cob that
have bearing on de husking and shelling performance of maize thresher were determined. These
include length, breadth, thickness, bulk density, spherity and terminal velocity for maize kernel;
and cob size and grain-to-non grain ratio for maize cob. In addition, an effort was also made to

determine the force required to detach husk and a single kernel from maize cobs using a
pendulum device which was specially developed for this purpose. This design is preferred,
because of its rapid operation, high human-energy expenditure, high breakage factor for the
kernels. [16]
2.4 Summarize literature review

No Authors Year Title Description
1 Evaluation and The limitation of this mechanism is it has low
Dagninet 2017 demonstration of maize shelling efficiency because when the small size
Amare Sheller’s for small-scale maize is feed in to the cylinder then it passes
farmers. directly without shelling.
2 Modification and testing The limitation is low efficiency for maize shelling,
Hussen 2015 of Jimma adjustable hand shelling capacity is low or unit shelling and also it is
Abagissa maize Sheller. dangerous or tedious to work.
3 hand operated maize Its limitation is low shelling efficiency because the
Sheller maize is shelled one by one. These activities involve
Karikatti 2015 a lot of drudgery as these are done manually. The
et al maize shelling with the tool makes women's lives
difficult and yields very low level of output.
4 Shelare 2015 Power operated maize In Ethiopia this power operated not good to use
et al Sheller these machines because of their cost.
5 hand operated maize The limitation of this project is it needs two persons
Singh 2013 dehusker-sheller or workers but in our project we reduce man power
it needs one worker.
6 2010 Pedal operated maize explained operating speed of rotary maize Sheller
Twaris Sheller was optimized for its operation at higher operating
et al speeds in pedaling mode, It was concluded that the
operating speed of maize Sheller should be 70 to 80
r.p.m.

2.5 CONCEPT DEVELOPMENTS AND MODELING

2.5.1 Concept Developments
At the first part of this project, we had created a clear problem definition, to help us
progress in creating potential designs for a maize shelling device. After talking with several
people that were experts in their fields, we gained some insight into where some of the
importance of our ―design specifications‖ should be focused.
The second, the group focused on coming up with possible designs that were
manufacturable, maintainable, and most importantly, effectively did the task they were made to
do. Between 4 and 5 ideas were produced by each person in the group for possible designs, while
ensuring that each produced their own ―uniqueness‖
Once sketches were produced for each idea, they were compiled into an excel sheet,
where the ideas would be graded on the design parameters chosen. Each design parameter
received a weighting that we believed would help most effectively pick a design that would
actually work, work well, be safe, easily be manufacturable, and is maintainable.
The design matrix helped us narrow down the better concept, where the matrix had
shown the most efficacious design. After some collaboration between the groups, we had come
to the conclusion that this final design was easy to operate, extremely maintainable, and
effectively accomplish the task of shelling corn.
Concept A: Table Grater – Shelling
The proposed table grater device would consist of a piece of sheet metal with grating
surfaces punched into it, then rolled into a cylinder shape with the cutting edges lining the inside
of the cylinder. This would be firmly mounted into a hole in a table in a vertical orientation with
the cutting edges pointing up. Using a piece of wood or stone, an ear of maize would be pressed
down through the grating device, shearing off the kernels into a bin below. This device could be
made from materials found in Ethiopia somewhat easily and would be inexpensive as long as a
table could be spared to cut a hole in. It is likely to work but has the potential to jam under
loading of larger ears of maize. Safety would be high as long as hands are not put into the

cylinder. The device could be maintained fairly easily, although if the cutting edges were
sufficiently dulled the grating device would need to be replaced. The whole device is essentially
as large and heavy as the table used. Since it is a fixture in a table, probability of theft is low. A
disadvantage of this design is the human power necessary to sufficiently push the ear of maize
through the grating device.
Input
Output
Figure 2-5 Table grater shelling mechanism
Concept B: Roller Edge with spring loaded – Shelling
The proposed roller edge Sheller device consists of a piece of sheet metal with a
rectangular hole that is slightly smaller than an ear of maize cut into the middle, with one of the
long edges sharpened into a cutting edge. A rolling mechanism would also be constructed and
attached to a pulley handle or some other powering device. The roller would press the ear of
maize into the sheet metal with cutting edge, and then rotate it along the cutting edge to cut off
the kernels with the help of spring loaded to control the gap between the roller and cover. This is
a relatively simple and inexpensive design and easy to maintain but creating a roller that works
properly could be a problem. The lifespan of the device is also of concern, as the cutting edge
would quickly dull and that portion of the project would need to be replaced. Range of motion
would be a smooth rotation of the powering device.

Figure 2-6 Roller Edge with spring loaded – Shelling
Concept C: Corn Tower – Shelling
The corn tower is a device designed to facilitate the shelling of maize. Husked ears of
corn are placed into a vertical or inclined tube. The corn is then gravity fed through a cast hand
held Sheller which is being rotated by an external power source. As the kernels fall off they fall
through a wire mesh and are collected in a dish below Once the ears have been shelled they are
now small enough to fall through the device and slide down an exit ramp away from the device.
The corn tower can be powered by an external handle with appropriate pulley system to aid in
human power required.
Figure 2-7 Corn Tower – Shelling

Concept D The combination of corn sharpener, handheld or hopper with internal teeth for the
Sheller.
Figure 2-8 Concept D
1. Design Specifications or criteria to develop our concept
Table 2-1 Concept development criteria
Design Weight Impact

parameter
Function 5 The device must effectively accomplish its task of de kernelling corn. It
also must accomplish this task more efficiently
Delivery 5 A design of the device and a working prototype Must be takes short time.
date
Safety 5 The device has to be safe to use.
Human 4 Since this device will derive its power from human input it must be
factor comfortable, safe, and easy to use.
Life span 4 This device should be able to last a minimum of 7 years.
Environme 4 Since this device will most likely be stored outside it must be able to
ntal withstand the elements, including wind, rain, and intense heat.

condition
Manufactur 4 No complex manufacturing techniques should, constructed from
ability available materials, or easy to obtain.
Product 4 The initial costs this device has to be low.
cost
Quality 4 The device has a high quality design to allow for extended use of the
machine.
Reliability 4 The target is to minimize the need for repairs and make any necessary
repairs possible to complete by virtually anyone in less time.
Maintenan 4 As with repairs, the device should require minimal maintenance.
ce
Mechanical 4 The main component of this design will undergo large amounts of
loading repeated mechanical loadings.
Energy 3 Since the device will be human powered and possibly by malnourished
consumptio women, it must consume minimal energy.
n
Operating 3 Any operating and maintenance instructions should be minimal,
instructions universal, and well documented in a permanent fashion.
Size 3 The device should be small enough to fit
Personnel 3 The device must be able to be operated by two people or less.
Operating 3 The device should require minimal operating costs.
cost
Transportat 3 The device must be able to be transported short distances on foot by 2
ion people
Weight 2 The device should be light enough.

2. Decision matrixes
To assist in selecting a conceptual design to focus on and develop further a decision

matrix was one of the tools utilized to rank potential designs. Several categories were selected to
judge each design on from the list of design specifications. The design specifications that were
selected represented that fields that would vary the most between each potential design and
would have the greatest impact on selecting a design. The original list of conceptual designs was
narrowed down to a smaller list to evaluate using the decision matrix.
Table 2-2 Decision metrics for selecting conceptual design
Shelling Functi Delivery Safet Human Life Environmental manufactur

Concepts on(5) date(5) y (5) factors(4) span(4) conditions(4) ability(4)
Concept A 2.5 3.5 3 2 1 1 1.5
Concept B 3 2 4.5 3 3 3 3.5
Concept C 4 4 3 3.5 2.5 2 4
Concept D 4.5 4 4 4 4 4 3
Shelling Quali Product Reliab mainten Mechanical Energy

Concepts ty (4) cost (4) ility(4) ance(4) loading(4) consumption(3)
Concept A 1.5 2.5 3 2 1 1
Concept B 2 2 3 2 3 1
Concept C 2 2 1.5 2.5 4 2
Concept D 4 3.5 3.5 3 3 3
Shelling Operati sizes(3) person Operatio Transportat Weight (2) Total(71)

Concepts ng (3) nel(3) n cost(3) ion (3)
Concept D 2 2 2.5 2.5 2.5 1 41.5
Concept B 2 2 2 2 1 1 45
Concept C 2 2 1 1.5 2 1 46.5
Concept D 3 2 3 2 2 1 60

3. Final selected concept
After much collaborative analysis of the decision matrices above our team decided to
select concept D the combination of corn sharpener, handheld or hopper with internal teeth and
Corn tower design for the Sheller, and the handle to pulley for the power system and also we use
bevel gear to transmit perpendicular rotation. The Sheller is selected according to their high
ranking in their respective decision matrices.

CHAPTER THREE
3 METHODOLOGIES AND MATERIAL SELECTION

3.1 Methodology
Generally, the complete hand operated maize Sheller machine will be manufactured in
pilot scale and the following procedures will be implemented. First, the data collection from rural
farmer Sheller needs associated with agricultural operation. And then assessing the previous
different literature reviews about maize Sheller machines and mechanisms. Different parts of
maize Sheller will be designed using appropriate software and then based on the design the hand
operated maize Sheller will be manufactured by us with the help of technical person as like
welding.
During the design of this machine the geometrical analysis is very important with regard
to mathematical modeling and designs are considered as the force analysis and momentum
principle. After design and manufacturing then finally it will be tested by using the researcher to
be taken different duties. Finally, the determination on whether their problem will be solved and
the efficiency of the maize Sheller will be determined using appropriate techniques.
In the process of designing and manufacturing hand operated maize Sheller machine, the
following methodologies are important procedures and will be followed in this project.
1 Data collection
 Primary data the data collection from rural farmer Sheller needs associated with
agricultural operation.
 Secondary data then assessing the previous different literature reviews about
maize Sheller machines and mechanisms. By reading different reference books,
from website, from internet access and from different handbook.
2 Modeling and material selection

3 Scientific design analysis
4 Mechanical drawing (in both assembly and detail drawing)
5 Fabrication
6 Test the fabricated machine

3.2 Material selection

Following are some of the steps of material selection process which are usually followed
in regular designing tasks
 Establishing Selection Criteria
 Short listing material
 Evaluate material on selection criteria
 Selecting best material
1. Establishing Selection Criteria
In material selection process for any engineering design task, establishing selection criteria is
first step in which a selection criterion for material selection is establish and usually it consists of
properties required to full fill design requirements. Following are the some of the criteria on which
all materials will be selected. Such as: - mechanical Properties, manufacturing Properties,
environmental Properties, economic aspects, and availability issue.
Mechanical properties have first position in selection criteria as they will define mass, strength
and performance of the product. After mechanical properties manufacturing properties of material
are test as they will define the proper manufacturing process and the cost of the manufacturing
process of product and thus will affect the final cost of the product. Environmental properties are
third in selection criteria as they will define the environmental effect of material from which the
produce will be manufacturing. It is very important to select a material that effect the environmental
lest during its life span and death period. Economic aspects material will define the cost of raw
material and will have great impact of the final cost of the product. Material cost should be kept as
low as possible in order to keep the final product low and make the product cost effective.
Availability issue is also very important is material selection the selected material should be easily
available in local market. This will reduce the transportation cost and will save a lot of time required
for material transportation.
2. Short Listing Materials

There is slot of materials that have the required potential to be used as base material for a
particular product production. It is very difficult to study each and every material available for
product. So make this process easy, usually three to four materials are short listed form all
available materials and this is done by studying similar products.

A. Mild Steel
The amount of carbon typically found in mild steel is 0.05% to 0.25% by weight, whereas
higher carbon steels are typically described as having carbon content from 0.30% to 2.0%. If any
more carbon than that is added, the steel would be classified as cast iron. Less carbon means that
mild steel is typically more ductile, machinable, and wieldable than high carbon and other steels,
generally resulting in less tensile strength than high carbon and alloy steels. Almost all the
required criteria for/ hopper, frame, thresher, shaft, and handle/ are included in this material.
Therefor we select mild steel for all the above parts.
B. Cast Iron
1. Has high carbon content 7. It has Good casting properties
2. It is available in large quantities 8. It has excellent anti-vibration
3. It has good Sensibility 9. It has excellent resistance to wear
4. It has very low notch sensitivity 10. It has Low stress concentration
5. It bears Low cost 11 It is Durability
6. It has Resistance to deformation
Almost all the required criteria for/ bevel gear, bearing, pulley/ are included in this material.
Therefor we select cast iron for all the above parts.
C. Rubber
materials are available in various durometers (hardness’s), tensile strength, and ... Highly
flexible, durable, and versatile, butyl is available in an array of grades and ...
Chloroprene rubber (CR) is a synthetic rubber that is also known by the trade name ... This
model does not provide accurate predictions of the material response, CR can be vulcanized in
the presence of zinc oxide alone; however, long-term flexibility and good mechanical properties;
and CR answers to all such needs. A tensile strength is high and assures reliability and
durability over the lifespan of the end product. Because urethanes are tough, they can be used in
thinner gauges when compared to vinyl /v-belt/.
3. Material Evaluation
All short list materials are evaluated on the base of selection criteria establish for a
particular product. Marks or points are given to each material based on its performance in each

and every field of selection criteria. Material are arranged on descending sequence based on their
overall marks. In most of cases first material is selected for the production of product but in some
case first two material or one which easy available is used for production.
3.2.1 Material selection for shaft, Sheller, and hopper

The shelling unit was fixed on the center of the machine. It consisted of thresher or
Sheller, and hopper with internal thread for shelling, bearing and bearing rods for transmission of
power and movement of shelling assembly. The side of the shelling assembly was covered for
safety purposes. The list of various materials that were used is as follows:
1. The selection criteria for shaft, thresher and hopper:- Strength, Resilience to
corrosion, Machinability, Ductility, Cost of the material, and Availability of the material
2. The most common materials used for shaft. Sheller and hopper:- Mild steel, carbon
steel, alloy steel, aluminum, etc.
Table 3-1 Evaluation material selecting for shaft, Sheller and hopper
Materials Strength Resilience to Machinability Ductility Cost Availability

corrosion
Mild Steel Medium Good Excellent High Low High
Carbon Steel Low Good Good Medium Medium Medium
Alloy Steel Low Good Good High High Medium
Aluminum High Good Good Medium Medium High
Based on evaluation, mostly the material which contains 75% of the above properties is
mild steel; therefore, we select mild steel for designing the thresher and hopper.
3.2.2 Bevel gear Material selection

 The Material selection criteria for bevel gears based on:- Strength, Ductility, Wear
and Tear resistance, Machinability, cast ability, Cost, and Availability
 The Materials used for bevel gear:- There are a lot of materials that can be used for
fabrication of bevel gears but out of all those material following are the most common
materials used for gear manufacturing. Cast iron, Steel, cast steel, Alloy Steel, Aluminum
Alloy

Table 3-2 Evaluation of material selection for bevel gear
Materials Machinabili Strength Ductility Wear Availability Cost

ty resistance
Steel Good High Good Good Low High
Cast Steel Not good Medium Good Good Low High
Alloy Steel Good High Good Good Medium Low
Cast Iron Satisfactory High Good Good High High
Aluminum Alloy Excellent Medium Satisfactory High Medium
Based on the evaluation shown above cast iron is the best material for this project as it
has highest yield strength, high wear resistance, and lowest cost. Cast iron is the material select
for fabrication of bevel gears.
3.2.3 Material for Plummer block or bearing

A Plummer block or bearing housing is a pedestal used to provide support for a rotating
shaft with the help of compatible bearings & various accessories. Housing material for a
Plummer block is typically made of cast iron or cast steel.
 The Selection criteria:-Coefficient of friction, Strength and Relative Hardness,

Corrosion Resistance, Availability of Material, and Cost of Material:
 The materials used for bearing-The most common materials used for bearing
Aluminum Alloys, Copper-Lead Alloys, Cast Iron and Rubber.

Table 3-3 Evaluation material selection for bearing
Material Coefficen Strength Hardness Corrosion Availability Cost

t of (compressive Resistance
friction fatigue)
Cast Iron Low Medium High Good High Low

Rubber Low Low Medium Excellent Medium High
Copper Lead Low Medium Medium Good Low Medium
Alloy
Aluminum Low Low Medium Excellent Medium Medium
Alloy
has medium strength, high wear resistance, low thermal conductivity, lowest cost and it is
available in Ethiopia. Then cast iron is the material select for manufacturing of this bearing.
3.2.4 Material for v belt

 The Selection criteria: - Flexibility, Reliable and durable, Tensile strength, and
Availability and Cost
 The material used for V-belts: - with a trapezoidal or V shape, made of rubber,
neoprene, and urethane synthetic materials,
Table 3-4 Evaluation material selection for v belt
Materials Flexibility Reliable and Tensile Availability Cost

durable strength
Rubber High Good High High Low

Neoprene Medium Good Medium Low High
Urethane Medium Good Medium Low High
Synthetic

Based on the evaluation shown above rubber is the best material for this project as it has
high tensile strength, high wear resistance, flexible, lowest cost and it is available in Ethiopia.
Then rubber is the material select for manufacturing of this v belt.
3.2.5 Material for v belt drive or pulley and handle

 The material selection criteria’s for pulley: - Excellent resistance to wear and
corrosion, Good machinability, Cost of material, Availability of the material, Strength,
Light in weight
 The Common materials for pulley:- aluminum, brass, cast iron, plastic, steel, and zinc
alloy.
Table 3-5 Evaluation material selection for pulley and handle
Materials Resistance to wear Machina Cost of Availability of Strength Weight

and corrosion bility material the material
Aluminum High Good Low Good Medium Low
Brass Medium Good High Good Medium Medium
Cast Iron High Excellent Low Excellent Medium Low
Plastic High Good High Good High Low
Steel Medium Good High Good High High
Zinc Alloy Medium Good High Good High Medium
Steeliness Steel High Good High Good High High
has medium strength, good machinability high wear resistance, low thermal conductivity, lowest
cost and it is available in Ethiopia. Then cast iron is the material select for manufacturing of this
v belt drive and handle.
3.2.6 Frame structure

This formed the main skeleton of the machine. It was made strong enough to resist the
maximum magnitudes of compressive, tensile and impact forces and simultaneously support the
other parts of the machine fixed on it. The proper material used for Frame Structure Different
Mild steel used to formed frame structure (Solids rods and Hollow pipes).

Table 3-6 shows the parts of the machine as well as the material selected for each part.
No Components Functions Materials

1 Hopper with Serves as storage for the maize to move into the crushing Mild steel
internal teeth chamber.
2 Frame The structure used to support all the bodies Mild steel
3 Thresher or Sheller To shell and give out grains. Mild steel
4 Shaft It transmits torque and motion from the pulley to turn the Mild steel
crusher
5 Handle Used as an input to rotate the pulley Mild steel
6 Bevel gear To transmit perpendicular torque or speed. Cast iron
7 Bearing To allow free movement of the shaft. Cast iron
8 Pulley or belt drive It transmits the torque from the handle to the Shaft. Cast iron
9 V belt To transmit the torque from the input man power to the pulley. Rubber

CHAPTER FOUR
4 DESIGN ANALYSES
4.1 Part Description
1. Frame (tower) – is made up of mild steel which used to support all part of the machine.
2. Main (vertical) shaft – is a shaft coupled with pinion bevel gear and which used to rotate
the Sheller by transmitting the rotational motion from gear to Sheller.
3. Sheller or thresher – is a part which used to thresh maize grain from cob.
4. Hopper – a part which used to hold and shell the maize.
5. Shaft 3 (pulley supporter) – is used to support the larger pulley.
6. Larger pulley - a part which used to transmit rotational speed.
7. Handle – a part used to feed human hand force to the machine in a rotational mechanism.
8. Pulley shaft-a part that transmits motion by holding large gear and smaller pulley.
9. Pulley one –a small pulley that used to multiply a rotational motion to the larger gear.
10. V-belt-it transmits a motion from larger pulley to smaller pulley.
11. Key- used to proper assemble in shaft and gear.
12. Larger bevel gear-that fixed with pulley shaft and give motions to the smaller gear in
perpendicular way.
13. Pinon gear-transmit motions in to vertical shaft that given from larger gear.
4.2 Design Considerations

The parameters considered in the design of this modified hand operated maize Sheller
include the following;
 Overall height of the machine to facilitate ease of operation by a rural farmer of average
height.
 Overall width and breadth of the machine for purposes of storage space in the rural
farmers’ granaries. and weight of the equipment for portability.
 Geometry of maize cob and grain.
 Stress and force analysis of parts.
The design of this maize Sheller is based on consideration of design specifications whose
choice is based a number of factors that include the availability of construction materials needed

for a further fabrication of the work presented in this paper, cost of such materials, desired size
of the machine for Ergonomics of using it, machinability factor which includes, installation,
simplication, and durability as well as the prolonged life of using the machine. These design
specifications include the following;
4.3 Geometric Analysis

4.3.1 Handle Design
This handle is used to rotate or to give rotation for the first larger pulley. The average
rpm developed by a human being by hand is 50rpm.from reference Jansen, A., Slob, P. (2003).
The selected material used for this handle is cast iron.
Figure 4-1 handle free body diagrams
To find the volume we use the formula of cylinder, then approximate volume of handle is-
, then h=450+170+350=970mm and radius of 15mm
To find the weight of handle, the density of mild steel is ρ=7800kg/m3
 The mass of handle
m = ρ * v = 5.3* 10-4 * 7800 kg/m3 = 3.87kg
 The weight of handle
W = mg =3.87* 9.81= 37.96N

4.3.2 Pulley geometric analysis

V-belts are made of fabric, cords and are molded in rubber while the pulleys are made of
cast iron in order to reduce the overall weight of machine According to Indian Standards (IS:
2494 – 1974), the V-belts are made in five types i.e. A, B, C, D and E. The dimensions for
standard V-belts are shown in Khurmi Table 20.1. The pulleys for V-belts may be made of cast
iron or pressed steel in order to reduce weight.
Table 4-1 Dimensions of standard v belt according to IS, 2494 – 1974.
Type Power ranges Minimum pitch diameter of Top width Thickness Weight per meter
of belt in kw pulley (D) mm (b) mm (t) mm length in N
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 -
We take some parameters from standard the diameter of the smallest pulley (driving) is
100mm, face width for both pulley is 50mm and the velocity ratio vr=3
The ratio between the velocities of the driving and the driven pulley is given as; (from sheigly
mechanical design).
…………………..……………………………………………………………… (1)
Where = the diameter of driven pulley.
= the diameter of driving pulley.
X= central distance between driving & driven pulley
= the rotational speed of driven pulley.
= the velocity ratio of pulley.
= the rotational speed of driving pulley.

To find the diameter of driven pulley by using velocity ratio vr=3 and diameter of driving pulley
mm
Then,
Figure 4-2 pulley free body diagram
To find the volume for the largest pulley we use the formula of cylinder
Where, r is the radius of largest pulley is 150mm, h is the face width =50mm
To find the volume of the smallest pulley D =100mm
The total volume of the pulley
To find the mass of pulley, density of cast iron is ρ=7300kg/m3

The weight of the pulley is
4.3.2.1Type of belt
There are many types of belt used now days, yet the following are important from the
subject point of view.
Flat belt: - is mostly used in factories and workshops, where a moderate amount of power is to be
transmitted from one pulley to another when the two pulleys are not more than 8 meters a part.
Circular belt or rope: -the circular belt is mostly used in the factories and workshops, where a
great amount of power is transmitted, from one pulley to another, when the two pulleys are more
than 8 meters apart.
V-belt: - this belt is mostly used in 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.
Advantage of V-belt
 The V-belt drive gives compactness due to the small distance between centers of pulley
 Since the V-belt are made endless and there is no joint trouble, therefore the drive is
smooth
 It provides longer life,3 to 5 years
 It can be easily installed and removed
 The operation of the belt and pulley is quiet
 The belt has the ability to cushion the shock when machines are stored
 The V-belt may be operated in either direction with tight side of the belt at the top or
bottom. The center line may be horizontal, vertical or inclined.

4.3.3 Design of Bevel Gear

When gears are used to transmit motion between intersecting shafts, some form of bevel
gear is required. A bevel gear set is shown below in Fig. Although bevel gears are usually made
for a shaft angle of 90◦, they may be produced for almost any angle. The teeth may be cast,
milled, or generated. Only the generated teeth may be classed as accurate. the selected material
for gear is cast iron.
Figure 4.7 Bevel gears.
The terminology of bevel gears is illustrated below in Fig. The pitch of bevel gears is
measured at the large end of the tooth, and both the circular pitch and the pitch diameter are
calculated in the same manner as for spur gears. It should be noted that the clearance is uniform.
The pitch angles are defined by the pitch cones meeting at the apex, as shown in the figure. They
are related to the tooth numbers as follows:
Figure 4-3 Terminology of bevel gears. [17]

The gear ratio can be determined from the number of teeth, the pitch diameters
……………………………………………………………………….. (2)
If the mating gear has more teeth than the pinion, that is the gear ratio i =2 is more than one, then
the smallest number of teeth ZP on the pinion without interference is given by from [17].
√ ………………………………………………… (3)
Where k = 1 for full-depth teeth, 0.8 for stub teeth and β= pressure angle. For a 20◦ reference
pressure angle, with k = 1, and we take as i =2,
ZP=14.2, we can say that 15 teeth. But in our project we use the number of teeth of the pinion is
20 teeth, and module m=3mm
Then to find the pitch diameter of the pinion gear DP=m Z2=3*20=60mm, we can calculate all
the terms of this bevel gear,
The pitch diameter of the largest gear is DG=i DP=2*60=120mm,
Reference cone angle
, then 63.44◦,
, then
Cone distance
Face width b It should not exceed , then we take as b=22mm
Addendum but
⁄ ⁄

Dedendum, –
Tip diameter
Hub diameter of the bevel gear is determined from standard table, for largest gear 3in=76mm and
for pinion 1.75in=44mm.
The length through bore is also determined from table, then for largest gear 1.68in=42mm and
For pinion 1.79in=45.46mm.
To find the volume of bevel gear we use the approximate formula of cylinder.
Where R is the pitch radius of bevel gear
For largest gear
For pinion gear
The total volume of gear
Mass of gear
Where ρ is density of cast iron =7300kg/m3

4.3.4 Design of thresher or Sheller

The threshing unit for this design is composed of two parts; the main part is thresher is
mechanically attached to the secondary shaft and rotating against a rigid spiked metallic surface.
the second part is hopper with teeth is at rest. Those two parts create forces; hence this forced
friction results to the threshing of maize kernels from the cob.
To find the volume of thresher we use the formula of cylinder and for teeth we use the
formula of triangular prism.
………………………………………………………………………………….. (4)
…………………………………………………………………………... (5)
Figure 4-4 thresher
Where r is radius of cylinder =150mm
h is height of cylinder = 700mm
a is base of the teeth triangle =25mm
c is height of teeth triangle = 25mm

Total volume of thresher is
To find the mass of thresher
, ……………………………………………………………………….….. (6)
where ρ is the density of mild steel =7800kg/m3
4.3.5 Design of hopper

The hopper is designed to be fed in a vertical position only. The material to be used for
the construction is mild steel sheet metal, which is readily available in the market at affordable
costs. The hopper has the shape of a frustum of a cone truncated at the top, with top and bottom
having circular forms. This is illustrated by the following diagram.
Figure 4-5 Hooper

For the top side by considering the maximum diameter of cob with grain, the outer
diameter of the hopper is 580mm, at the base of the teeth 574mm and at the top of the teeth is
500mm.
For the bottom side by considering the minimum diameter (25mm) of shelled maize or
cob the outer diameter of hopper is 320mm, thickness is 3mm, and at the top of teeth 250mm.
The volume of hopper
To find the volume of hopper we use the formula of the shape frustum of cone,
, ……………………………………………………………… (7)
Where h is the height of hopper =700mm,
r1 is the radius at top of hopper =580mm/2=290mm
r2 is the radius at bottom of hopper =330mm/2=165mm
To find the volume of hopper teeth, by using the formula of prism
Where w is the width of teeth = 35mm
l is the length of teeth =20mm
h is the height of teeth =700mm
Then the total volume of hopper with teeth is

To find the weight of hopper first find out the mass
Where ρ is the density of mild steel=7800kg/m3
M = 24.163kg
To find the storage capacity of hopper by finding the average volume of cob with grain
Figure 4-6 Maize cob with grain. [23]
The average length of this maize 15.42cm and the average diameter 4cm
The volume is calculated as where r is radius of maize =2cm
And we calculate the volume of hopper
Determination of weight resisting on the shaft and weight of grain resisting on the shaft are
determined as follows:
Where r1 is the largest radius of hopper = 252mm, r2 is the smallest radius of hopper = 127mm
and r3 is the radius of thresher = 100mm. then

The to find the number of cob with grain
To find the mass of cob with grain the density of cob = 721kg/m3 and density of grain = 760
kg/m³ and the average radius of grain is 7.5mm
Volume of a grain by considering the shape as sphere
The mass of one grain is
i.e. density of grain maize is equal to 760 kg/m³.
The mass of cob with grain (the average)
Weight of cob with grain, g is gravity = 9.81m/s2
4.3.5.1 Stress on the hopper

To find the stress analysis we consider the weight of the other parts or materials acting on
the hopper such as weight of maize grain, (strength of material)
, ……………………………………………………………………………………………………………………… (8)
where F is the force on the hopper that is the weight of the cob with grain which is and area
of the hopper is calculated as by using frustum of con formula,
√ √

The maximum tensile stress of mild steel is 800 – 840 mpa , but the calculated tensile stress
170.4 pa is less than that of the maximum stress. Therefor the hopper design is over safe.
4.3.6 The Main Frame

The main frame supports the entire weight of the machine, Material selected for supporter is
mild steel having the following properties; 200-220Gpa, assume for our design E=210Gpa, The Ultimate
Tensile Strength σult=800 - 840MPa.assume σult=800Mpa and factor of safety for steel can be selected
from standard fs = 2. Yield Stress is 247 MPa and. It is a low carbon (0.050.025% carbon) that comes
in affordable price. In this design work, 5mm thickness is used to give the required rigidity.
The total weights carried by the main frame are: The two design factors considered in
determining the material required for the frame are weight and strength
 Weight of the hopper ( ⁄ ),
 Weight of the shaft (Wsh = mg=86N),

 Handle (W = 37.96N), Sheller (Wshel =129.5N),
 The gears (Wg = 30.4N) and pulley (Wpull = 193.307),
 Weight of maize cob with grain that feed in to the hopper .
The sum of all the weight

Figure 4-7 Frame or supporter
Assumption, the frame is considered as column with one end free and the other end fixed then
critical load is given by
⁄( ⁄ )
Crushing load= 𝞭c*A, where 𝞭c is crushing yield stress in compression = equivalent

length of the column=z*l, k least radius of gyration. Bucking will occur if Wcr < Wapp or 𝞭 > 𝞭all
from previous analysis the weight applied on the supporter frame is the sum of whole weight of
the Sheller. , this weight is distributed among 4 supporting structures, so
This load is applied vertically, the critical load is calculated as
The support is mild steel with a square cross section length of frame from Euler’s formula of
crippling load the polar moment of inertia is given by. (refer Khurmi, 2006)
……………………………………………………………………………………. (9)

But for square cross section , substituting the above value a = 40mm
Let us check the normal stress with the allowable one
since ,
Then the design is safe.
4.4 Force analysis

4.4.1 Hand crank
The crank is the mechanical means of rotating the shaft during manual operation. The
design of the crank bar is based on the strength. It is required that the crank bar has enough
strength to be able to resist failure due to tension or shear. For suitability, comfort and optimum
operation of the shelling machine a length of 0.97 m was chosen for the crank which is a mild
steel rod of 40mm diameter.
The required power is generated by a man rotates handle, the average rotational speed developed
by a human being is (N1=50 rpm) and also the average power generated by a human being is
(P=1hp= 745.7W).
But the required power to rotate handle is the rating was determined by calculation results.
Power transmitted by shaft, angular speed and torque was determined (Khurmi)
……………………………………………………………………………….. (10)
Then T1=Fr

………………………………………………………………………………… (11)
Where F is the required force to rotate hand crank, m is the sum mass of pulley, gear, shaft and
Sheller and r is the height of handle.
Then T2=34.19Nm
4.4.2 Pulley force analysis and v-belt selection

The most widely used types of pulleys material for flat belts are: cast iron pulleys, steel
pulleys, wooden pulleys, paper pulleys, and fast and loose. But for this design we use cast iron
pulleys, because of their low cost. The cast iron pulleys are generally made with rounded rims.
The rim is held in place by web from the central boss or by arms or spokes. The cast iron pulleys
may be solid.
D2 = 100mm and center to center distance C is 612.07mm, Calculation of P1 and P2.
P2
P2
Figure 4-8 pulley free body diagram

T2 = (P1-P2) × (D2 /2), 34.19Nm = (P1-P2) × 50*10(-3)
(P1 – P2) = 683.8N…………………………………………………………….…….............. (12)
P1 /P2 =eμθ, where μ is coefficient of friction =0.3 and
θ is calculated by
P1 /P2 = e0-3*3.47=2.832
P1 =2.832×P2………………………………………………………………………………….. (13)
By equating the two equations we get, 2.832P2 – P2 = 683.8N
P2 = 373.25N, P1 =2.832×518.4N= 1057.04N
4.4.2.1 for standard belt selection

We select rubber belts because one of the principle advantages of these belts is that they
may be easily made endless. And these belts are found suitable for saw mills, paper mills where
they are exposed to moisture. The rubber belts are made of layers of fabric impregnated with
rubber composition and have a thin layer of rubber on the faces and these belts are very flexible.
 The mass density of rubber belt is 1140kg/m3.

Length of belt (L) [17]
√ …………………………………………….... (14)
4.4.3 Bevel Gear Force Analysis

In determining shaft and bearing loads for bevel-gear applications, the usual practice is
to use the tangential or transmitted load that would occur if all the forces were concentrated

at the midpoint of the tooth. While the actual resultant occurs somewhere between the midpoint
and the large end of the tooth, there is only a small error in making this assumption. For the
transmitted load, this gives [1]
………………………………………………………………………………………. (15)
Where T is the torque and rav is the pitch radius at the midpoint of the tooth for the gear under
consideration. The forces acting at the center of the tooth are shown in Fig. The resultant force
W has three components: a tangential force Wt, a radial force Wr, and an axial force Wa. From
the trigonometry of the figure,
Wr = Wt tan β cos γ
Wa = Wt tan β sin γ
Where β =pressure angle
γ =reference cone angle
Figure 4-9 Bevel-gear tooth forces. [17]
The speed of the pinion gear is , where N1 is the speed of largest gear which is the same
as the speed of the smallest pulley N1=150rpm, then .

And also the torque of the smallest pulley is the same as the torque of the largest gear
TG=34.19Nm
The resultant force W has three components: a tangential force Wt, a radial force Wr, and an
axial force Wa. From the trigonometry of the figure,
 For the largest gear
To find the transmitted load we can use this formula Wt is
Radial force Wr is , where β is the reference pressure angle β=20◦ and

the reference cone angle
An axial force
Wa is
 For pinion gear
To find the transmitted load we can use this formula Wt is
Radial force Wr is , where β is the reference pressure angle β=20◦ and the
reference cone angle =26.56◦
An axial force Wa is
The output torque from the pinion TP is

4.4.4 Bevel Gear stress analysis

Design a straight-bevel gear mesh for shaft centerlines that intersect perpendicularly, to
deliver 537.1W at150 rev/min with a gear ratio of 1:2, normal pressure angle of 20◦, using a
design factor of 2. The load is uniform use a pinion of 20 teeth. The material is to be cast iron
and the teeth are to be crowned. The reliability goal is 0.95 with a pinion life of 50000 hr.
4.4.4.1 Bevel gear wear

 Gear contact stress
……………………………………………………… (16)
Where ZE= elastic coefficient (N/mm2)1/2
b= face width of gear
ZI =Pitting Resistance Geometry Factor
ZXC = crowing factor for pitting resistance
KA = over load factor
KV = Dynamic factor
= load distribute factor
= size factor for pitting resistance
 To calculate ZE elastic coefficient (N/mm2)1/2
√ ……………………………………………………………………………. (17)
ν2, ν1 are Poisson’s ratio for materials of gear and pinion, respectively. Then, the Poisson’s ratio
for materials of gear and pinion mild steel is 0.28.

Table 4.10 Modulus of Rigidity [7]
Material Shear modulus (G)

106psi GPa
Aluminum alloys 3.9 27
Aluminum 6061-T6 3.8 24
Aluminum 2024-t4 4.0 28
Beryllium copper 6.9 48
Brass 5.8 40
Bronze 6.5 44.8
Cadmium - 19
Carbon steel 11.2 77
Cast iron 5.9 41
chromium - 115
concrete 3.0 21
E1 and E2 = Young’s moduli for pinion and gear respectively, N/mm2. Then, the Young’s moduli
of mild steel for pinion and gear is E1 = E2 =41 GPA=41000 N/mm2.
Then ZE is
Table 4-2 To calculate KA over load factor is from this table, source ANSI/AGMA 2003 B97
Characteristics Characteristics of load on driven machine

of prime mover Uniform Light shock Medium shock Heavy shock
Uniform 1.00 1.25 1.50 1.75 or higher
Light shock 1.10 1.35 1.60 1.85 or higher
Medium shock 1.25 1.50 1.75 2.00 or higher
Heavy shock 1.50 1.75 2.00 2.25 or higher
This is for speed decreasing drivers but for speed increasing drivers, add 0.01(Z2/Z1)
Then KA = 1.00 + 0.01(20/40) = 1.005

 To calculate KV Dynamic factor
√
( ) …………………………………………………………………………. (18)
⁄
Where , and (vet) is the pitch-line velocity
at outside pitch diameter, expressed in (m/s):
⁄
Then assume that Qv = 7, then
√
( )
The maximum recommended pitch-line velocity is associated with the abscissa of the terminal
points of the curve in Fig. 15–5 (17):
⌊ ⌋
where vet max is in m/s.
⌊ ⌋
vt < vt max, that is, 0.9425< 23.85 m/s, therefore Kv is valid.
 To calculate load distribute factor
KHβ = Kmb + 5.6(10−6) b2…………………………………………………………………………………………. (19)
Where {
because of and b is face width =22mm
Then KHβ = 1.25 + 5.6(10−6) 222 = 1.253mm2
 To calculate Crowning Factor for Pitting (Zxc)
The teeth of most bevel gears are crowned in the lengthwise direction during manufacture

to accommodate to the deflection of the mountings.
{ , Then
 To calculate Size Factor for Pitting Resistance (Zx)
{ ,
Then, Zx=0.00492*22+0.4375=0.5457mm
 Contact geometry factor ZI
Figure 4-10 Contact geometry factor ZI [17]
Contact geometry factor I (ZI) for conflux straight-bevel gears with a 20◦ normal pressure
angle and a 90◦ shaft angle. (Source: ANSI/AGMA 2003-B97.)
From the above figure by using the number of teeth of pinion and gear we got the approximate
value ZI = 0.078
Then we calculate the gear contact stress
( ) …………………………………………………… (20)
√( ) ⁄

 Gear wear strength
Where permissible bending stress
= allowable contact stress
= stress cycle factor for pitting resistance
= hardness ratio factor
= contact factor of safety
= temperature factor
= reliability factor for pitting
 allowable contact stress
Table 4-3Table Allowable Contact Stress Number for Iron Gears, sac ( ) Source:
ANSI/AGMA 2003-B97.
Material Designation Typical Allowable contact

material ASTM ISO Heat Minimum Stress Number
Treatment Surface (allowable), sac
Hardness (σH lim) Ibf/in2
(N/mm2)
ASTM A48 ISO/DR 185
Cast iron Class 30 Grade 200 As cast 175 HB 50 000 (345)
Class 40 Grade 300 As cast 200 HB 65 000 (450)
Ductile ASTM A536 ISO/DIS 1083
(nodular) Grade 80-55-06 Grade 600-370- Quenched 180 HB 94 000 (650)
iron 03
Grade 120-90-02 Grade 800-480- And tempered 300 HB 135 000 (950)
02
The Allowable Contact Stress Number for cast Iron grade ASTM 80-55-06 Gears is 650N/mm2.

 To calculate Stress-Cycle Factor for Pitting Resistance (ZNT)s
{ , then Life goal 106 cycles,
 Hardness-Ratio Factor (ZW)
Most of the time for steel gear pairs of approximately equal hardness ZW = 1.
 Temperature Factor (Kθ)
{ Then
 Reliability Factors (ZZ) and (YZ)
From sheigly mechanical design Table 15–3 displays the reliability factors. Note that CR = √KR
and ZZ = √YZ Logarithmic interpolation equations are.
{ , then by taking R = 0.99
Then ZZ = √1 =1
, …………………………………………………………………………… (21)
by taking the factor of safety
 Wear factor of safety
 Based on strength
, Therefore our design is safe because the calculated factor of safety is
greater than that of the given factor of safety.

 Based on Wt can compared to SF

,
4.4.5.2 Gear bending stress

……………………………………………………………………… (22)
Where = transmitted load
= bending stress
= size factor for bending strength
= outer transferred module
= length wise curvature factor for bending
= geometric factor for bending
= face width of gear is 22mm
Calculation Size Factor for Bending (Yx)
{ , then met = 3mm
 Bending Strength Geometry Factor (YJ)
From sheigly this Figure shows the geometry factor YJ for straight-bevel gears with a 20◦
pressure angle and 90◦ shaft angle.

Figure 4-11 Bending Strength Geometry Factor (YJ),Then YJ = 0.2
 Lengthwise Curvature Factor for Bending Strength (Yβ)
For straight-bevel gears,
Kx = Yβ = 1
Therefore, the gear bending stress is
 Gear bending strength
………………………………………………………………………………... (23)
Where = permissible bending stress
= bending stress (allowable)
= Stress-Cycle Factor for Bending Strength
= reliable factor for bending strength
= bending safety stress

Table 4-4 Bending stress (allowable)
Material Designation Minimum Bending Stress

Material ASTM ISO Heat Surface Number (allowable),
Treatment Hardness sat , (σF lim) Ibf/in2
(N/mm2)
ASTM A48 ISO/DR 185
Cast iron Class 30 Grade 200 As cast 175 HB 4500(30)
Class 40 Grade 300 As cast 200 HB 6500(45)
Ductile SASTM A536 ISO/DIS 1083
(nodular) Grade 80-55-06 Grade 600- Quenched 180 HB 10000(70)
iron 370-03
Grade 120-90- Grade 800- And 300 HB 13500(95)
02 480-02 tempered
Then by taking the value class 30 or grade 300, from this table we get hardness is 175 HB and
bending stress number is
 Stress-Cycle Factor for Bending Strength
Then nL=106,
Then the bending strength is by taking the factor safety 1.5
 Bending factor of safety
Based on strength

Based on Wt is same as SF, nB=1.75
Therefore, we can conclude that the threat to each gear and to the mesh by comparing the
bending factor of safety (SF) and the square of wear factor of safety (SH)2. and
.
Then, this implies that the gear threat is from bending.
4.4.6 Thresher or Sheller force analysis

The shelling force is calculated by a given value of Sheller torque is 17.094Nm and radius of
Sheller is 100mm = 0.1m.
…………………………………………………………………………. (24)
Table 4-5 Results of force measurements averages. [4]
Force measurement, right hand in N

Hand Little finger Ring finger Middle finger Index finger Thumb
Average 551.2 30.8 37.9 55.1 56.7 107.7
Force measurement, left hand in N
Hand Little finger Ring finger Middle finger Index finger Thumb
Average 505.2 28.4 37 53.7 60.4 109.5
In average the human thumb develops a force of 107.7N and we know that a maize grain can
shelled from cob by human thumb, although the force generated by our machine is 170.94N
therefore this force is greater than the force of human thumb so it can shell easily.
The production capacity (feed rate) is generally expressed by (Journal of American Science
2017)
…………………………………………………………………………….. (25)
Where q = production capacity (feed rate)
𝞓 = thickness of plant mass layer at the entrance to the Sheller, 25mm

= density of the plant mass, 721kg/m3
= Velocity of the Plant mass entering the Sheller, m/s
L = length of the drum is 700m
Velocity of the Plant mass entering the Sheller, m/s
4.5 Design of shaft

A shaft is a rotating machine element which is used to transmit power from one place to
another. The power is delivered to the shaft by some tangential force and the resultant torque (or
twisting moment) set up within the shaft permits the power to be transferred to various machines
linked up to the shaft. In order to transfer the power from one shaft to another, the various
members such as pulleys, gears etc., are mounted on it. These members along with the forces
exerted upon them causes the shaft to bending. In 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 splines.
Design of shafts of ductile materials based on strength is controlled by maximum shear

stress theory while that of brittle materials is by maximum normal stress theory. In practice
shafts are usually subjected to fluctuating torque and bending moments. In order to design such
shafts like line shafts the combine shock and fatigue factors must be taken into account. For a
solid shaft made from ductile material having little or no axial loading, the shaft diameter is
obtained from ASME code equation according to Khurmi and Gupta, 2008. We consider the
following design parameters:
1. Permissible Shear Stress (Ʈ)

2. Torsional Moment (Mt)
3. Bending Moment
4. Shaft Diameter on Strength Basis
4.5.1 Shaft one (Shelling shaft)

For this shaft is bevel pinion gear and the Sheller. Shaft design depends on the size of
rotating element and forces acting on it. The system of interest is separated from the surrounding
and connections are replaced by forces, Reactions in bearings & force diagram
To find the reaction forces at the bearing, we consider the Sheller weight as an axial load,
the weight of the Sheller is 129.5N, and the other forces are produced from gear acting on this
shaft such as axial force is WA= 92.74N, the total axial force is Fa 192.5N + 92.74N = 285.29N
radial force is WR = 185.51N, transmitted force is WT = 569.83N
 At horizontal (x) axis
 Free body diagram of reaction forces
Figure 4-12 free body diagram
We assume that the length of the shaft 1065mm, then to calculate the reaction force at B,
by taking the moment at A is equal to zero.
but WR = 185.51N
To get the reaction force at A. by taking the summation of force in X axis is zero.

, then FBX = 190.72N and WR = 185.51N
 At vertical axis or Z axis
 Free body diagram of reaction forces
Figure 4-13 Free body diagram
Then to calculate the reaction force at B, by taking the moment at A is equal to zero.
To get the reaction force at A. by taking the summation of force in X axis is zero.
Therefore, all the reaction forces at bearing A and B are

 Bending moment at X axis
To draw the bending moment diagram we can calculate the moments for each the main
point, then from distance x = 0 up to 0.035m there is no moment means M = 0, because of there
is no acting load on the shaft.
From distance x = 0.035 up to1.005m, the moment is calculated as
From distance x =1.005m up to 1.035m the moment is calculated
From distance x = 1.035m up to 1.065m the moment is calculated

 Bending moment at Z axis
Then from distance z = 0 up to 0.035m there is no moment means Mz = 0, because of

there is no acting load on the shaft due to this distance.
From distance z = 0.035 up to 0.575m, the moment is calculated as
From distance z = 0.575m up to 1.005m, the moment is calculated as
From distance z = 1.005m up to 1.035, the moment is calculated as

From distance z = 1.035 up to 1.065m, the moment is zero.
X axis Bending moment diagram
Figure 4-14 Shear force and bending moment diagram for x axis

Z axis
Figure 4-15 shear force and bending moment diagram for z axis
Therefore, the maximum bending moment is calculated by taking the maximum moment from
each axis,
z axis and
Then the maximum bending moment is the resultant of the two,

√( ) ……………………………………………………………………… (26)
When the shaft is subjected to an axial load (F) in addition to torsion and bending loads
as in shafts for driving bevel gears, then the stress due to axial load must be added to the bending
stress (σb).and then we can find out the diameter of shaft by considering the combination of the
torsional, the maximum bending moment and axial force. for a hollow shaft subjected to
fluctuating torsional and bending load, along with an axial load, the equations for equivalent
twisting moment (Te) and equivalent bending moment (Me) may be written as
√( ) ……………………. (27)
( )
[ √( ) ]
…………………………………………...………………………. (28)
Where T = maximum torque is also calculated as T = 17.094Nm
Maximum bending moment is calculated from the above,
F is the axial force acting on shaft F = 285.29N
Me = equivalent bending moment
Equivalent twisting moment
σb = bending stress
Maximum shear stress
d = diameter of shaft
But this shaft carries axial tensile load, then α = 1, and also it is solid shaft then k = 0 and d0=d.

Therefore, the equation becomes,
√( )
[ √( ) ]
Table 4.6 Recommended values for Km and Kt.
Nature of load Km Kt
1. Stationary shafts
(a) Gradually applied load 1.0 1.0
(b) Suddenly applied load 1.5 to 2.0 1.5 to 2.0
2. Rotating shafts
(a) Gradually applied or steady load 1.5 1.0
(b) Suddenly applied load with minor shocks only 1.5 to 2.0 1.5 to 2.0
(c) Suddenly applied load with heavy shocks 2.0 to 3.0 1.5 to 3.0
Km = Combined shock and fatigue factor for bending, and
Kt = Combined shock and fatigue factor for torsion
Then from the above table by considering the shaft is gradually applied or steady load, Km = 1.5
and Kt = 1.0
Permissible shear Stress (Ʈ), by taking the yield strength of mild steel is 200N/mm 2 from
standard material properties table and also factor of safety is 2.
( )
√( )
√( ) , use both sides power of 2.

( ) ( )
By using math equation calculator, we got the value of therefore the diameter
of the shaft is 30mm.
4.5.2 Shaft two (transmission shaft)

A solid Shaft made up of mild steel having yield strength as 250 Mpa is choose In this
project we have two shaft, the first shaft is coupled to one end is the smallest pulley rotating at
150 rpm and the other end is the largest bevel gear and the second shaft is coupled to the pinion
bevel gear it rotates by 300rpm.
This shaft is coupled to one end is the smallest pulley rotating at 150 rpm and the other end is the
largest bevel gear.
Where WT is tangential load =569.83N
Wr is radial load = 92.74N
Wa is axial load = 185.51N
PZ and PY are the pulley tensions applied on shaft resolved from P1 and P2 because P1 is applied
by angle 55.45º and P2 is by 36.41º
To find PZ and PY, resolve P1 and P2 by angle 55.45º and 36.41º respectively.
Y axis
PY =PY1+PY2 = 599.47+300.39 = 899.86N

Z axis
Then PZ =PZ1+PZ2 = 870.61+221.54 = 1092.15N
Find the bearing load at x, y and z axis
x axis the force applied on shaft at x axis is only axial force of largest gear W a is axial load =
185.51N.
∑ Then Wa - FBX=0
FBX=185.51N
Y axis the force applied on shaft at y axis is radial force of largest gear W r =92.74N and
PY=899.86N
Figure 4-0-16 free body diagram
Then,

The negative indicates the direction of force
Z axis the force applied on shaft at Z axis is tangential force of largest gear WT =569.83N and
Pz=1092.15N
Figure 4-17 force free body diagram
Then,
The bending moment diagram is constructed from left to right, at various planes considering the
forces that are acting on the plane and those on the left side of the plane. Counterclockwise- and
clockwise moments are assigned positive and negative signs respectively.
1. Bending Moment:
The bending moments in the vertical plane or y axis
Moment at A

Moment at between A and C
Moment at B
Moment at between C and B
Moment at C
Moment at D

Figure 4-18 shear force and bending moment diagram

 Horizontal-z-axis
 Moment at A
Moment at between A and C
Moment at B
Moment at between C and B
Moment at C
Moment at between C and D

Moment at D

Z axis
Figure 4-19 bending moment diagram
From the bending moment diagrams, the maximum bending moment is observed at the center of
A and C. The resultant bending moment at the center plane A and C is
BMR at √ Then and
BMR at AC = (4.1882) + 4.12)1/2 =5.861Nm

2. Permissible Stress (Ʈ): -Shear
Ʈ = 0.5 (Syt) / F.S = 0.5(200) /2 = 50N/mm2
3. Torsional Moment (Mt): -
The first shaft is coupled to one end is the smallest pulley rotating at 150 rpm, the power is
calculated from the above 537.1W
4. Shaft Diameter on Strength Basis:
When the shaft is subjected to an axial load (F) in addition to torsion and bending loads
as in shafts for driving bevel gears, then the stress due to axial load must be added to the bending
stress (σb).and then we can find out the diameter of shaft by considering the combination of the
torsional, the maximum bending moment and axial force. for a hollow shaft subjected to
fluctuating torsional and bending load, along with an axial load, the equations for equivalent
twisting moment (Te) and equivalent bending moment (Me) may be written as
√( )
( )
[ √( ) ]
Where T = maximum torque is also calculated as T =
Maximum bending moment is calculated from the above,
F is the axial force acting on shaft F = 185.51N
Me = equivalent bending moment

equivalent twisting moment
σb = bending stress
maximum shear stress
d = diameter of shaft
But this shaft carries axial tensile load, then α = 1, and also it is solid shaft then k = 0 and d0=d.
Therefore, the equation becomes,
√( )
[ √( ) ]
Then, from the above table the recommended values for Km and Kt.
Km = Combined shock and fatigue factor for bending, and
Kt = Combined shock and fatigue factor for torsion
Then from the above table by considering the shaft is gradually applied or steady load, Km = 1.5
and Kt = 1.0
Permissible shear Stress (Ʈ), by taking the yield strength of mild steel is 177N/mm2 from
standard material properties table and also factor of safety is 2.
( )
√( )
√( ) , use both sides power of
2.

( ) ( )
By using math equation calculator, we got the value of therefore the diameter
of the shaft is 30mm.
4.6 Design of key

A key is a piece which is inserted between the shaft and hub or boss of the pulley, gear
and Sheller 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 fastening and are
subjected to considerable crushing and shearing stress.
In our design we select square sunk key because of easy to manufacture, short length
which can fit with our design and it have less cost than other key.
Then design the keyway in the Sheller shaft extension.
4.6.1 Design of square key

The sunk key is provided half in the keyway of the shaft and half in the keyway of the
hub or boss of the pulley. Material selected is mild steel with crushing stress 112 MPa and shear
stress 50 MPa.
Figure 4-20 key free body diagram

Considering the diameter of shaft d=30mm.
Width of the key
Thickness of the key

Considering shearing of the key
We know the shearing strength (Torque transmitted) of the key
…………………………………………………………………………….. ( 29)
And torsional shearing strength (Torque transmitted) of the shaft

……………………………………………………………………………… (30)
In order to determine the length of the key to transmit full power of shaft, the shearing
strength or torque transmitted of the key is equal to the torsional shear strength or torque
transmitted of the shaft.
, the key material is same as that of the shaft, then τ = τ1. And
w =7.5, d = 30mm
Now considering crushing of the key

We know that shearing strength or torque transmitted of the key
To find length
Taking the larger of the two values, we have the length of key is 42mm.

4.6.2 Design of key way

A little consideration will show that this key way cut into the shaft. Reduces load
carrying capacity of the shaft. This is due to the stress concentration near the corners of the key
way and reduction in the cross-section area of the shaft.in other word, the tensional strength of
the shaft is reduced. The H.F Moore relation used for determining the weakening effect of the
key-way is based on the experimental results.
( ⁄ ) ( ⁄ ) …………………………………………………………... (31)
( ⁄ ) ( ⁄ )
The strength of the shaft with key-way
And shear strength of key
The torque developed by the strength of shaft with key way is less than that of the torque of key
such that ,
Therefore, the design is safe.
4.7 Bearing Selection

A bearing is a machine element that constrains relative motion to only the desired
motion, and reduces friction between moving parts. There are many types of bearings, each used
for different purposes. These include ball bearings, roller bearings, ball thrust bearings, roller
thrust bearings and tapered roller thrust bearings. in our project we select the tapered roller
bearing because, tapered roller bearings combine the advantages of ball and straight roller

bearings, since they can take either radial or thrust loads or any combination of the two, and in
addition, they have the high load-carrying capacity of straight roller bearings. The tapered roller
bearing is designed so that all elements in the roller surface and the raceways intersect at a
common point on the bearing axis.
Tapered roller bearings are capable of carrying both radial and axial loads; but largely
used for applications where axial load component predominates. They are often used in pairs to
take the thrust load in both directions. Since the inner and outer race contact angles are different,
there is a force component, which drives the tapered rollers against the guide flange resulting in
heating due to friction. Therefore, these bearings are not suitable for high speeds. Tapered roller
bearings are ideally suited to withstand repeated shock loads. Multiple-row tapered roller
bearings have high radial-load carrying capacity.
Where: L10 = life of bearing for 90% survival at one million revolutions;
L = required life of bearing in million revolutions (mr);
N = rotational speed (rev/min);
C = basic dynamic load rating (N);
P = equivalent dynamic bearing load (N);
Fr = actual radial bearing load (N);
Fa = actual axial bearing load (N).
The radial loads FrA and FrB are the vector additions of FyA and FzA, and FyB and FzB,
respectively:
WT is tangential load =569.83N
Wr is radial load = 92.74N
Wa is axial load = 185.51N

The bearing reactions at A are
√( ) √
√( ) √
Since bearing B is unloaded, we will start with R = RA = 0.95.
Table 4-6 To compare dynamic equivalent radial load. [17]
*If mFae is positive, K=KB; If mFae is negative, K= KA.
Note: FrAB is the radial load on the two-row assembly. The single-row basic dynamic radial load
rating, C90, is to be applied in calculating life by the above equations.
……………………………………………………………… (32)
To determine the , ;
For double direction bearings the radial load factor is 1.9 and axial load factor is 0.55, noting that m = +1
for direct mounting and Fae to the right is positive,

We use the upper set of equations in Table 11–6 to find the thrust loads:
……………………………………………………………………… (33)
The dynamic equivalent loads PA and PB are
From sheigly Fig. 11–16 for 150 rev/min at 55◦C, fT = 0.4., fv = 1.01. For use in Eq. (11–16), a3l
= fT fv = 0.4(1.01) = 1.32. The catalog basic load rating corresponding to the load–life–reliability
goals is RD as √ for each bearing. For bearing A, the catalog entry C10 should
equal or exceed, the shaft speed is 150 rev/min, the desired life is 50 000 h
⁄
[ ] ………………………………………………………... (34)
⁄
[ ]
From figure 11–15 Catalog entry of single-row straight-bore Timken roller bearings, by using the
calculated C10 Tentatively select the bearing identical to bearing A, which will work: KB = 1.95
and C10 = 12 100 N.
For bearing B, the catalog entry C10 should equal or exceed
⁄
[ ]

From figure 11–15 Catalog entry of single-row straight-bore Timken roller bearings, by using the
calculated C10 Tentatively select the bearing identical to bearing A, which will work: KB = 2.3
and C10 = 18400 N.
Trial 2: Use KA = KB =1.95 from tentative bearing selection. The sense of the previous inequality
is still the same, so the same equations apply:
For bearing A, from Eq. (11–17) the corrected catalog entry C10 should equal or exceed
The dynamic equivalent loads PA and PB are
For bearing A, from Eq. (11–17) the corrected catalog entry C10 should equal or exceed
⁄
[ ]
Although this catalog entry exceeds slightly the tentative selection for bearing A, we will keep it
since the reliability of bearing B exceeds 0.975. In the next section we will quantitatively show
that the combined reliability of bearing A and B will exceed the reliability goal of 0.95
For bearing B,
⁄
[ ]
Finally, we Select cone and cup 2687 and 2631, respectively, for both bearing A and B. Note
the effective load center is located at a = −9.4 mm, that is, 5.8 mm into the cup from the back.
Thus the shoulder-to-shoulder dimension should be 150 − 2(9.4) = 131.2 mm.

We select the proper bearing which is fit with the shaft bore diameter, then the shaft
diameter at bearing is 25mm.
Figure 4-21 Geometry for bearing.
The required dimensions are

d = 25.4mm db =33.5mm
D = 68.26mm da =31.5mm
T = 22.225mm r = 1.3mm
R = 1.3mm C = 19.05mm
B = 25.433mm Db =53.0mm
Da=60.0mm
4.8 Manufacturing process
Manufacturing process: -is a very fundamental subject since it is of interest not only to
mechanical engineers but also to engineers from other discipline of engineering. There are
various manufacturing processes by which a product can be made. There is more than one
process is available for manufacturing a particular product and we can make a proper choice of
the process which would require lowest manufacturing cost. Due to this we used the following
two manufacturing process used these are: -
1. Process operation: -transform work materials from one state of completion to a more advance
operation that change the geometry properties or appearance of the starting material.

Table 4.17 manufacturing process
no Name Quantity Type of operation

Step(1) Step (2) Step(3) Step(4) Step(5)
1 Pulley 3 Cutting Turning Drilling facing
2 Shaft 2 cutting Turning facing
3 Frame 1 cutting Bending Welding facing
4 Hopper 1 cutting Rolling Welding
5 Handle 1 cutting Turning Bending facing
6 Thresher 1 cutting Turning Threading facing Drilling
7 Key 3 cutting Facing
Type of machine used in process operational: -
1. Lathe machine 3. Welding machine (arc welding)
2. Bending machine 4. Rolling machine
2 Assembly operation: -join two or more components to create one entity.
4.9. Maintenance and Lubrication

The contacting surfaces in rolling bearings have a relative motion that is both rolling and sliding
and sliding, and so it is difficult to understand exactly what happens
The purpose of an antifriction bearing lubricant may be summarized as follows:
 To provide a film of lubricant between the sliding and rolling surfaces

 To help distribute and dissipates heat
 To prevent corrosion of the bearing surfaces
 To protect parts from the entrance of foreign matters
Either grease or oil may be employed for a lubricant

Table 4.18 Comparison of grease and oil coolant
 Grease  Oil
Temperature is less than 200 °F Temperature is high
The speed is low Speeds are high
Simple bearing enclosure are desired Bearing type is not suitable for Grease
Depend on its comparison, we select grease
 Gear Drive Maintenance
Three ingredients are basic to gear drive maintenance:

1. Proper Support & Mounting
2. Proper Alignment of Input & Output
3. Proper Lubrication
4. Proper Support & Mounting
The housing is designed to locate the bearings in relation to each other, support the shafts
and contain the lubricant. It is not very rigid & distorts if not leveled & mounted on the proper
foundation. Shimming & uniform leveling on the firm foundation will provide proper tooth
contact & bearing alignment.
 The alignment of Gearbox with its driving & driven member is extremely important in providing
long life.
 The single most common cause of the failure of gearing or gear drives is probably inadequate
lubrication.
 Viscosity & Viscosity Index is the key consideration when selecting the oil.
 The oil temperature at the mesh point is at least 100 C higher than the sump temperature.
 Touch & Feel the vibration and temperature.
 See the condition of tooth flank for surface damage.
 Surface damage could be in the form of pitting, spalling, scoring, ridging, rippling or other visual
sign of deterioration.
 The type of damage leads us to what corrective action needs to be taken.
 Discoloration of gears and bearing is always the sign of lack of lubrication.
 Effective maintenance program focusing on support, alignment, lubrication & inspection will go
a long way in obtaining the long operating life of the gearbox.

4.10 working principle

This model is done by solid work software. And it’s working principle is a worker gives
an input power by rotating handle, then the first largest pulley rotates and also the rotation is
transmitted in to the smallest pulley by belt, the smallest pulley gives rotation for the largest
bevel gear by connecting shaft and then the bevel gear and pinion gear transmit perpendicular
rotation to the main shaft and then the main shaft rotates, the thresher also rotates inside hopper,
the maize inputs in to hopper then it shelled by thresher or Sheller and hopper teeth.
Figure 4-26 working principle

CHAPTER FIVE
5. RESULT AND DISCUSSION

5.1. Result
Table 4.19 result
No Dimensions
Parts quantity Materials
Length(mm) Width Thickness Diameter(mm)
(mm) (mm)
1 Hopper 1 700 3 Top dim = 580 Mild steel
Bott dim = 330
2 Frame 4 1500 50 3 None Mild steel
3 Sheller 1 700 None 200 Mild steel
4 Shaft 1 1 1065 None Max =30 Mild steel
min=25
5 Pulley 1 525 None Max = 30 Mild steel
shaft min=25
6 Larger 1 None 50 None 300 Cast iron
pulley
7 Small 1 None 50 None 100 Cast iron
pulley
8 Belt 1 1868.84 38 8 None Rubber
9 Larger gear 1 None 22 None 120 Cast iron
10 Pinion gear 1 None 22 None 50 Cast iron
11 Bearing 4 None 19.05 21.33 68.26 Cast iron
12 Key 1 3 50 7.5 7.5 None Mild steel
13 Handle 1 970 None 40 Mild steel

5.2. Cost analysis
No Part name Material Mass of Price/kg Total price (birr)

material (kg) (birr)
1 Handle Mild steel 3.87 43.5 168.35
2 Pulley or belt Cast iron 19.695 40.6 799.6
drive(2)
3 Bevel gear Cast iron 3.1 40.6 125.86
4 Thresher or Mild steel 13.2 43.5 574.2
Sheller
5 Hopper with Mild steel 26.163 43.5 1138.09
internal teeth
7 Shaft(2) Mild steel 8.77 43.5 381.49
8 V- belt Rubber 1.2 46.11 55.33
9 Frame Mild steel 53 43.5 2305.5
10 Bearing(4) Cast iron 7.48 40.6 303.68
11 Square key(3) Mild steel 0.23 43.5 10
Total cost = sum of all parts cost +other unexpected cost
Total cost = 5862.1 + 1000 = 6862.10 birr

CHAPTER 6
6. CONCLUSION AND RECOMMENDATION

6.1 Conclusion
It is with full confidence to say that the grain mill machine will work efficiently, if it is
manufactured or produced properly according to our design. This machine has the capacity to
grind with high efficiency and it is better than the conventional finger palm shelling
method which has been reported to have 12.63 kg/hr. For designing this machine, the input
power is generated by rotating handle; this power can be transferred by the means of V-belt to
transfer power from handle to the shaft. This kind of machine is suitable for manufacturing.
Because there are light materials in weight, less cost, easily maintainable, so it is good for our
countries rural areas. This project helped us in improving our knowledge of designing machines
and machine elements.it has also helped us to recognize the value of economy in designing and
manufacturing machines. Thus the Sheller seems to solve the problem that rural and small scale
farmers regarding maize shelling.
As we know in our country almost 80% and above of the people are living in traditional
farming way. And this people particularly produced much amount of maize production. This
people consumes more time by processes of shelling a maize grain from cob. To be solve this
and like problem and to develop living style of rural farmers by one level we try to design and
manufacture this manual operated maize Sheller machine. After finish the manufacturing
process we can test its performance of machine and see its low cost, no need of electric power,
so it prefers in rural farmers and it will be distributed in less price to customers.

6.2 Recommendation
In our project work particularly we focused on rural area due to this study the machine
applicable manually without electric power source, but if anyone who wants to increase the
efficiency of machine can use electric power simply by adjusting electric motor with belt
mechanism. And also we would like to suggest for other designers to deal in detail by taking
more time, since this maize Sheller machine is very problem solver in our rural country to shell
maize from cob easily and effectively.
In comparison with conventional finger palm shelling method, the Sheller has a better
output capacity, reasonable shelling efficiency and kernel damage. It is therefore recommended
to demonstrate and pre-scale it up to solve the problem rural and small scale farmers are facing
for maize shelling at small scale levels.

REFERENCE
1. A text book of machine design, by R.S Khurmi and J.K Gupta edition
2. Ahlgrimm H.J., The genetic of maize evolution, Journal of Agricultural Engineering,
Volume 38(4),1997, pp68 -72.
3. Ali, Y., Singh, J., Soni, A. and Mahesh Wari, A.K. (1986). Economic and technical
feasibility of maize de husking and shelling. J. Agric. Engg., 23(1): 71-81.
4. Bretz KJ, Jobbágy Á, Bretz K. (2006) Equipment for investigation of hand and ﬁnger
tremor and finger forces.
5. Callister, William D., 1940- Materials science and engineering: an introduction / William
D. Callister, Jr.—7th ed. p. cm.
6. Dagninet Amare. (2017) Evaluation and demonstration of maize Sheller’s for small-scale
farmers.
7. Engineering Toolbox, (2005). Modulus of Rigidity. [online] Available at:
https://www.engineeringtoolbox.com/modulus-rigidity-d_946.html.
8. http:// www.google.com (searching unit)
9. Hussen Abagissa. (2015) Modification and testing of Jimma adjustable hand maize
Sheller research in Jimma Ethiopia.
10. Jansen, A., Slob, P. (2003). Human power comfortable one hand cranking, august.
11. Journal of American Science 2017; http://www.jofamericanscience.org.
12. Karikatti et al. (2015) found that de husking and shelling are important post-harvest
activities in maize crop.
13. Shelare et al. (2015) studied that there are many maize shelling techniques in India which
are used in our life.
14. Singh. (2013) examined that hand operated maize dehusker-sheller was ergonomically
evaluated with ten farm women to assess the physiological workload and its performance
in standing and sitting postures.
15. Tiwari et al. (2010) explained operating speed of rotary maize Sheller was optimized for
its operation at higher operating speeds in pedaling mode,
16. Sharma (2007) studied to developed such a machine and suggest the farmers to adopt
suitable values of crop and machine operational parameters for the optimum threshing.
17. J.E. Sheigly, Mechanical engineering design, 1986, 1st edition, McGraw Hill, N.Y

18. shttp://scienceq.org/journals/JAET.php.
19. Mechanization Asia, Africa & Latin America, Indian standard test code for power maize
Sheller’s (1974).
20. Performance evaluation of a power operated maize Sheller.
21. Singh, S.P and Singh, P. 2010. Hand operated maize de husker Sheller for farm women.
22. Wanjala, (2014) about manual Sheller’s.
23. Zoerb and Hall (1960) studied the physical and rheological properties of grain.
24. IJIRST –International Journal for Innovative Research in Science & Technology.
25. http://www.vidhataindia.com/maze_sheller.htm.
26. www.agroproductlimited.com
27. Bhandari V.B., „‟Design of machine elements‟‟.3rd edition, 2010.
28. ASME, (1995). Design of Transmission Shafting. American Society of Mechanical
Engineering, New York, NY USA.
29. Demeke M. Analysis of incentives and disincentives for maize in Ethiopia.
30. Richey, C.B., Johnson, L. and Hall, C.W. (1982): Agricultural Engineering Handbook.

APPENDIX
Part drawing
Part 1 - Sheller

Part two - Frame supporter

Part 3 –Smallest Pulley

Part 4 – Pulley shaft

Part 5 - The largest pulley

Part 6 - roller bearing

Part 7 - gearbox cover

Part 8 – Pinion gear

Part 9 - largest gear

Part 10 - Hopper

Part 11 – Handle

Part 12 – Key

Part 13 - main shaft

Part 14 - fixed shaft

Part 15 –V belt

Assembly drawing

Prototype

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DEBRE TABOR UNIVERSITY

DEPARTMENT OF MECHANICAL ENGINEERING

Project on: - Design and fabrication of Hand Operated Maize Sheller

1. Endaylalu Eyaye 1326/07

Advisor: Mr. Yusuf A.(Msc)

SUBMITION DATE 15/10/2011 EC

DEBRE TABOR, ETHIOPIA

Advisor name Examiner name

MECHANICAL ENGINEERING Page i

MECHANICAL ENGINEERING Page ii

MECHANICAL ENGINEERING Page iii

MECHANICAL ENGINEERING Page iv

3.2.4 Material for v belt ...................................................................................................................... 25

MECHANICAL ENGINEERING Page v

5.2. Cost analysis ..................................................................................................................................... 89

MECHANICAL ENGINEERING Page vi

Table 2-1 Concept development criteria ..................................................................................................... 16

MECHANICAL ENGINEERING Page vii

MECHANICAL ENGINEERING Page viii

Angular Velocity rad/s

a Base of Teeth Triangle m

c Height of Teeth Triangle m

Ncob Number of Cob with Grain -

MECHANICAL ENGINEERING Page ix

E Elastic Modules N/m2

σult Ultimate Tensile Stress N/m2

σy Yield Stress N/m2

β Pressure Angle rad

γ Reference Cone Angle rad

σH Gear Contact Stress N/m2

ZE Elastic Coefficient (N/mm2)1/2

Zi Pitting Resistance Geometry Factor -

Zxc Crowing Factor for Pitting Resistance -

KA Over Load Factor -

KHB Load Distribute Factor -

Zx Size Factor for Pitting Resistance -

MECHANICAL ENGINEERING Page x

σHP Permissible Bending Stress N/m2

σHlim Allowable Contact Stress N/m2

ZNT Stress Cycle Factor for Pitting Resistance -

Zw Hardness Ratio Factor -

SH Contact Factor of Safety -

Zz Reliability Factor for Pitting -

Yx Size Factor for Bending Strength -

met Outer Transferred Module m

Yβ Length Wise Curvature Factor for Bending -

Yl Geometric Factor for Bending Stress -

YNT Stress Cycle Factor for Bending Strength -

Yz Reliable Factor for Bending Strength -

q Production Capacity kg/s

Shear Stress N/m2

C Basic Dynamic Load Rating N

Km Combined Shock and Fatigue Factor -

KA Radial Load Factor -

KB Axial Load Factor -

YJ Geometric Factor for Bending -

MECHANICAL ENGINEERING Page xi

MECHANICAL ENGINEERING Page 1

MECHANICAL ENGINEERING Page 2