Eit-M: Design and Modeling of Crop Cutting Machine For Farmers

EIT-M
SCHOOL OF MECHANICAL AND INDUSTRIAL

ENGINEERING
Department of Mechanical Engineering
Thesis for degree program
Design and Modeling of Crop

Cutting Machine for Farmers
Prepared:
By: Adonay Meresa 161473/06
Ashenafi hadgu 161591/06
Advisor: Zebenay T.(Msc)

Declaration
We declare that the work, which is being presented in this project entitled (Design of wheat crop
cutting machine), is original work of our own and it is done by our effort. It has not been
presented for a degree of any other university and all the materials used for the project have been
duly acknowledged.
APPROVED BY:
Adviser: Zebenay teamrat (Msc)
Signature: _____________
Date 21/09/2010 E.C (29/05/2018 G.C)
PRIPERED BY:
Adonay meresa Signature: ____________
Ashenafi hadgu Signature:_____________
Date 21/09/2010 E.C (29/05/2018 G.C)
i
Acknowledgement
Full of grateful to God first. Secondly, we would like to thank our advisor Ins. Zebenay Teamrat
(MSc.) for his invaluable support and direction from the start until the end of this design project.
Not to forget our fellow friends who also helped us in a medium of giving suggestion, solution
and soon. With the strong efforts, strong inspirations and hardworking, finally, this design
project is successfully completed. Once again, thanks our supervisor and friends.
ii
Abstract
This title presents the concept for design and analysis of wheat crop-cutter machine. The wheat
crop-cutting machine is important stage in agriculture field. Currently in Ethiopia former used
conventional method for the wheat crop-cutting, i.e. the conventional method for wheat crop
cutting is as manually cutting using labour due to this problem are faced by farmers who
work on small fields while harvesting wheat crop as it takes a lot of time, labour and
effort to cut the wheat crop manually. Although harvesting machines are already available in
the market but these are quite large and costly. Since farmers with small lands have no such
large usage and also harvesting is done only once or twice in a year, it becomes difficult
for small farmers to afford such kind of a machine. So, it becomes essential to make a
portable and cost efficient wheat crop cutting machine. To achieve this aim, a lot of
literature review has been seen and a lot of ground research has been done in this project
where in various farmers of a village near aynalem were met and their problems were
understood. Based on all the findings, a design for a wheat crop-cutting machine has been
developed which is expected to help small scale farmer’s big time. The machine consists
of two stroke engine, shaft, V belt, pulley, conveyer and blade. It has cutting blades, which cut
the crop in a scissoring type of motion. It runs on two stroke engine of 0.75kw, this power from
two stroke engine, is provided through pulley and gearbox arrangement to the cutter. Collecting
mechanism consists of conveyor belt and reel mechanism, which is, powered by two-stroke
engine. This project also includes cost estimation of the wheat crop-cutting machine. This
harvester might be the solution to the problems faced by a small-scale farmer regarding cost and
labour implementation.
Keyword: Manual method, shaft, V belt, conveyer, Crop cutting, two-stroke engine, collecting
mechanism.
iii
Table of Contents
Declaration ....................................................................................................................................... i
Acknowledgement .......................................................................................................................... ii
Abstract .......................................................................................................................................... iii
List of Figure ................................................................................................................................. vi
List of Tables ............................................................................................................................... viii
Abbreviations ................................................................................................................................. ix
CHAPTER ONE ............................................................................................................................. 1
INTRODUTION ............................................................................................................................. 1
1.1. Problem Statement ............................................................................................................... 2
1.2. Objective of the Project ........................................................................................................ 2
1.2.1. General Objective .......................................................................................................... 2
1.2.2. Specific Objective ......................................................................................................... 2
1.3. Significance of Study ........................................................................................................... 3
1.4. Scope of the Study ............................................................................................................... 3
CHAPTER TWO ............................................................................................................................ 4
LITERATURE REVIEW ............................................................................................................... 4
2.1. Types of Traditional Harvesting Tools ................................................................................ 4
2.1.1. Sickle or "Reaping Hook" ............................................................................................. 4
2.1.2. Scythe ............................................................................................................................ 4
2.1.3. Cradle ............................................................................................................................ 5
2.1.4. McCormick Reaper ....................................................................................................... 5
2.1.5. Riding Type Self- Propelled Reaper ........................................................................... 10
2.1.6. Self- Propelled Vertical Conveyor Reaper .................................................................. 10
2.1.7. Self-Propelled Reaper Binder ...................................................................................... 11
CHAPTER THERE ...................................................................................................................... 12
METHODOLOGY ....................................................................................................................... 12
CHAPTER FOUR......................................................................................................................... 14
DESIGN CONCEPTS AND SELECTION .................................................................................. 14
4.1. Concept Development Process ........................................................................................... 14
4.2. Conceptual Design ............................................................................................................. 15
4.2.1. Model A ....................................................................................................................... 15
4.2.2. Model B: ...................................................................................................................... 16
4.2.3. Model C: ...................................................................................................................... 18
4.2.4. Model D: ...................................................................................................................... 19
4.3. Design Matrix..................................................................................................................... 21
4.4. Concept Selection............................................................................................................... 21
CHAPTER FIVE .......................................................................................................................... 24
DESIGN ANALYSIS ................................................................................................................... 24
5.1. Selection of Two Stroke Engine and Determining of Capacity of Cutter.......................... 25
5.2. Design of V- Belt and V-Grooved Pulley .......................................................................... 28
5.3. Design of Bevel Gear ......................................................................................................... 32
5.4. Design of Shaft ................................................................................................................... 37
5.5. Design of Key .................................................................................................................... 41
5.6. Design and Selection of Contact Ball Bearing ................................................................... 43
5.7. Design of Reel .................................................................................................................... 45
5.8. Selection of Wheat Crop Cutting Blade ............................................................................. 47
5.9. Capacity and Dimension of the Belt Conveyor.................................................................. 48
5.10. Design of Vertical Frame (Columns and Beam) .............................................................. 49
5.11. Design of Scotch Yoke..................................................................................................... 57
5.12. Design of Welding ........................................................................................................... 59
5.13. Wheel Selection ............................................................................................................... 61
CHAPTER SIX ............................................................................................................................. 63
COST ESTIMATION ................................................................................................................... 63
6.1. INTRODUCTION.............................................................................................................. 63
CHAPTER SEVEN ...................................................................................................................... 70
CONCLUSION AND RECOMMENDATION............................................................................ 70
7.1. Conclusions ........................................................................................................................ 70
7.2. Recommendation................................................................................................................ 71
REFERENCES ............................................................................................................................. 72
APPENDIXES .............................................................................................................................. 73
v
List of Figure
Figure1.1. Ethiopian farmers when they cutting-harvesting of crops ............................................. 2
Figure2.1. Reaping Hook ................................................................................................................ 4
Figure2.2. The Scythe ..................................................................................................................... 4
Figure2.3. The Cradle ..................................................................................................................... 5
Figure2.4. The World's First Reaper ............................................................................................... 5
Figure2.5. McCormick’s Patent Reaping Machine......................................................................... 6
Figure2.6. McCormick's Patent Reaping and Mowing Machine .................................................... 6
Figure2.7. McCormick Combination Reaper and Mower .............................................................. 7
Figure2.8. The Marsh Type Harvester ............................................................................................ 7
Figure2.9. McCormick Harvester and Binder................................................................................. 8
Figure2.10. McCormick Harvester and Binder............................................................................... 8
Figure2.11. McCormick Harvester and Binder............................................................................... 9
Figure2.12. McCormick-Deering Tractor Binder ........................................................................... 9
Figure2.13. McCormick-Deering Harvester-Thresher ................................................................... 9
Figure2.14. The Windrow-Harvester ............................................................................................ 10
Figure2.15. Riding type self- propelled reaper ............................................................................. 10
Figure2.16. Self- propelled vertical conveyor reaper ................................................................... 11
Figure2.17. Self-propelled reaper binder ...................................................................................... 11
Figure4.1. Manually operated crop-cutting machine with engine as power source to the machine
....................................................................................................................................................... 15
Figure4.2. Manually operated crop-cutting machine powered with electric motor ...................... 16
Figure4.3. Manually operated crop-cutting machine with solar system as power source to the
machine ......................................................................................................................................... 18
Figure4.4. Manually operated crop-cutting machine that has two stroke engine (small engine) as
power source to the machine......................................................................................................... 19
Figure5.1. Wheat crop passing through feeder conveyer ............................................................. 26
Figure5.2. V-belt and V-grooved pulley cross-section ................................................................. 28
Figure5.3. Belt .............................................................................................................................. 29
Figure5.4. Forces on a moving belt .............................................................................................. 30
Figure5.5. Cross-section of V-grooved pulley.............................................................................. 32
Figure5.6. Shaft ............................................................................................................................. 37
Figure5.7. Key .............................................................................................................................. 41
Figure5.8. Bearing ........................................................................................................................ 43
Figure5.9. Angular displacement of two successive tine bars ...................................................... 46
Figure5.10. Cutting blade ............................................................................................................. 47
vi
Figure5.11. Conveyor ................................................................................................................... 48
Figure5.12. Small pulley ............................................................................................................... 52
Figure5.13. Column ...................................................................................................................... 54
Figure5.14. Welded joint of frame ................................................................................................ 59
vii
List of Tables
Table4.1. Preparing relative importance of needs ........................................................................ 14
Table4.2. Material selection for Model A ..................................................................................... 16
Table4.3. Material selection for Model B ..................................................................................... 17
Table4.4. Material selection for Model C ..................................................................................... 18
Table4.5. Material selection for Model D ..................................................................................... 20
Table4.6. Concept screening ......................................................................................................... 22
Table4.7. Concept scoring matrix ................................................................................................. 23
Table5.1. Shear strength of wheat straw with the blade (Mpa)............................................. 25
Table5.2. Two stroke engine selection ......................................................................................... 27
Table5.3. Properties of V belt (IS 2494:1974) .............................................................................. 29
Table5.4. Dimensions of standard V-grooved pulleys according to IS: 2494–1974. ................... 32
Table5.5. Standard proportions in module (m) for the four gear systems. ................................... 33
Table5.6. Recommended values for Km and Kt. ........................................................................... 40
Table5.7. Proportions of standard parallel tapered and gib head keys. ........................................ 42
Table5.8. Equivalent Radial Load Factors for Ball Bearings ....................................................... 44
Table5.9. Dimensions and Load Ratings for Single-Row 02-Series Deep-Groove and Angular-
Contact Ball Bearings ................................................................................................................... 45
Table5.10. Specification of cutter blade ....................................................................................... 47
Table5.11. Relation between actual length (L) and effective length Le ....................................... 55
Table5.12. Stress concentration factor for welded joints.............................................................. 60
Table5.13. Stress for weld joints................................................................................................... 61
Table5.14.Wheel selection ............................................................................................................ 62
Table6.1. Result and discussion .................................................................................................... 69
viii
Abbreviations
F.s = Safety factor E = Modulus of elasticity
M = bending moment V=Volume
Equivalent twisting moment
= Fatigue factor for bending Basic or dynamic load rating
Torque Allowable tensile stress
= Fatigue factor for torsion Groove angle
A = Cross-sectional area Static tooth load
Allowable shear stress Pressure angle on gear
Strength in shear Coefficient of friction
Equivalent bending moment critical load
Power Speed (velocity) ratio,
Radial load Critical stress
Total volume flow rate s = Slip
Allowable crushing stress Bending stress
N = Speed D = Diameter
= Tangential load acting at the tooth Section modulus
Rpm = Revolutions per minute Angle of lap or contact
= Allowable static stress Face width
Angular speed Length
= Brinell hardness Centrifugal tension
Density Thickness
= Surface endurance limit
flexural endurance limit
Maximum tension Angle of lap or contact
D = Diameter Face width
Section modulus Length
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Design and Modeling of Crop Cutting Machine for Farmers
CHAPTER ONE
INTRODUTION
Agriculture is the backbone of the Ethiopian economy and therefore this particular sector
determines the growth of all the other sectors and, consequently, the national economy. On
average, crop production makes up 60% of the sector’s outputs whereas livestock accounts for
27% and other areas contribute 13% of the total agricultural value added. Small-scale farmers,
who practice rain-fed mixed farming by employing traditional technology, adopting a low input
and low output production system, dominate the sector. The land tilled by the Ethiopian small-
scale farmer accounts for 95% of the total area under agricultural use and these farmers are
responsible more than 90% of the total agricultural output. The small-scale farmers produce
94% of the food crops and 98% of the coffee, the latter being the leading export item for the
country[ ].
In order to increase the productivity of agriculture in Ethiopia a wide range of technology for
production of crops including soil cultivation, and cutting of crops, and the activities of proper
processing and marketing are used. Mechanization involves the use of an intermediate device
between the power source and the work. Current mechanization agriculture includes the use of
tractors, trucks, combine harvesters, airplanes (crop dusters), helicopters, and other vehicles.
Mechanized agriculture is the process of using agricultural machinery to mechanize the work of
agriculture, greatly increasing farm worker productivity. In modern times, powered machinery
has replaced many jobs formerly carried out by manual labor or by working animals such as
oxen, horses and mules.
Crop cutting machine is a mechanical device, which is used to cutting the dry cut stalks of grain
break steam or covering of trunk tree. This can be applicable for cutting of the crop such as
wheat, tef and others.
Crop cutting machine are used for harvesting of crops mostly at ground level. Crop cutting
machines are classified based on conveying of crops. It avoids fuel consumption, labor
requirement. As the population of Ethiopia increases day by day, there is increment of food,
vegetables so need of farm mechanization also increases, machineries provides more operations
in less time, but the machineries are very costly for the common man, it is not affordable for
them ,so manually operated machineries, equipment’s are also the most important factor.
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1.1. Problem Statement

In our country most farmers use different types of harvesting tools and equipment that are
manually operated like sickle that operated by human handwork.
Figure1.1. Ethiopian farmers when they cutting-harvesting of crops

This harvesting operation requires 50% of the investment on the particular crop goes to
harvesting the crop and its transportation due to increase in wages of the labor and reduce in
availability of labor leading to the high demand of the labor. So the ideas to reduce the dependent
on workers in this harvesting and to have easy and efficient of harvesting crops, this project
comes to solve all this problems where the new invention for machinery in harvesting which able
to reduce the workers, to increase productivity, to reduce the cost and to increase profit. There
are also related problems including: The process renders fatigue to the hand and produces
damages to the hands, as it is continuous process, it requires monotonous work, and it is time
consuming and laborious process so no one wants to do in today era.
1.2. Objective of the Project
1.2.1. General Objective
The main objective of this project is designing and modeling of crop-cutting machine for
farmers.
1.2.2. Specific Objective
 To design mathematically for each components of wheat crop cutting machine.
 To determine and calculate stress analysis, detail drawing of the wheat cutter machine
and assembly drawing of the machine by CATIA software.
 To prepare cost estimation of wheat crop cutter machine.
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1.3. Significance of Study

 To control the shortage of labor in rural areas.
 Reduce the human effort.
 To reduce harvesting cost.
 Reduce the time during harvesting.
 Safety to use( preventing damage of cutting finger using sickle)
 To have easy harvesting of wheat crops.
1.4. Scope of the Study
This project will be designed and modeled based on studies conducted by referring the existing
reference books and mechanical software. The main scope of this thesis is starting from
conducting literature review, design analysis of the components up to conducting modeling and
manufacturing drawing and economic investigation of the wheat crop-cutting machine.
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CHAPTER TWO
LITERATURE REVIEW
2.1. Types of Traditional Harvesting Tools
2.1.1. Sickle or "Reaping Hook"
A sickle is a curved, hand-held agricultural tool typically used for harvesting grain crops before
the advent of modern harvesting machinery. The inside of the curve is sharp, so that the user can
swing the blade against the base of the crop, catching it in the curve and slicing it at the same
time.
Figure2.1. Reaping Hook

2.1.2. Scythe
The scythe was the companion tool to the reaping hook or sickle. It was always used for
mowing grass but sometimes oats and barley were cut with it. It was not generally used for
cutting wheat. With the scythe, a man could cut up to three acres a day[ ].
Figure2.2. The Scythe
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2.1.3. Cradle
The cradle was the most efficient means of cutting grain before McCormick's invention of the
reaper. The cradle consisted of a broad scythe with a light frame of four wood fingers attached
to it. The advantage of the cradle was that by a turn to the left the operator could throw the
grain into a swath, ready to be raked and bound into sheaves. This improvement was
introduced in America about 1776, according to Professor Brewer of Yale, and was the
common instrument of grain harvesting as late as 1840. For cradling grain, two acres was
considered a day's work [2].
Figure2.3. The Cradle

2.1.4. McCormick Reaper
This McCormick reaper of 1831 shows the wide master wheel, which carried most of the
weight of the machine and, through ground transaction, supplied power to operate the reel and
the reciprocal knife. The world's first reaper incorporated seven basic principles, which have
ever since been found essential in virtually all grain-cutting machines.
While this first machine required only two people for operation (a person to ride the horse and
a man to rake the cut grain from the platform), it cut as much grain in one day as 4-5 men
with cradles or 12-16 men with reaping hooks. (mcCormick)
Figure2.4. The World's First Reaper

The McCormick Patent Reaping Machine of 1857 combined machinery for reaping and
mowing, and was built from 1852-1865. Its chief improvements over the 1831 reaper were
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seats for driver and raker, a cutting knife fabricated in sections rather than one piece, and an
all-metal main wheel. This machine also cut a wider swath than the first reaper and was pulled
by two horses.
Figure2.5. McCormick’s Patent Reaping Machine

The McCormick Patent Reaping and Mowing Machine were manufactured from 1852-1865,
with various improvements being incorporated from time to time. This specific machine
includes seats for raker and driver and cut a wider swath than McCormick's reaper of 1831.
Figure2.6. McCormick's Patent Reaping and Mowing Machine

The McCormick Automatic Self-Rake Reaper was originally patented in 1858 and was
manufactured and sold in large numbers from 1862 until about 1875 (when a more efficient
machine bought out by McCormick replaced it). The harvester, known as McCormick's "Old
Reliable," was a one-man machine, which released yet another person to aid in other harvest
jobs. Its automatic rake swept cut grain off the platform, depositing the grain in neat gavels on
the ground, ready to be bound into bundles by the hand binders. Here an "Old Reliable" of
1864 deposits neat gavels of grain on the ground to be bound by a crew of 4-5 men. An "Old
Reliable" of 1867[3] with its automatic sweep arm removed cut grain from the reaper
platform. This arm released one more man for other farm jobs.
The McCormick “Advance” Combination Reaper and Mower. This machine was
manufactured and sold by McCormick from 1869-1879 [3]. The "Advance," a combined
mower and reaper, had an automatic rake as part of the reel. Platform and reel were
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removable so that the machine could be used as a straight hay mower. This illustration shows
the machine for use as a reaper.
Figure2.7. McCormick Combination Reaper and Mower

The McCormick Marsh Type Harvester, built from 1875-1883, consisted of the same cutting
mechanism as McCormick's earlier reapers, with an elevator and binding platform added.
Two men rode on the platform, binding grain by hand as it was delivered to the by the
elevator. This machine was patented as early as 1858 but was not put into general use until
1875. With the Marsh type harvester, two men bound the grain while earlier harvesters had
required 4-5 men for binding.
Figure2.8. The Marsh Type Harvester

McCormick Harvester and Binder of 1876 at work in the field was the first practical self-
binder ever built. People traveled miles to see the first machine controlled by one man, which
cut and bound grain in a single operation. McCormick built and sold 50,000 of these binders
between 1877 and 1885.
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Figure2.9. McCormick Harvester and Binder

McCormick Harvester and Twine Binder manufactured in 1881[2]. This was McCormick's
first binder that tied the bundles with twine. After the development of this machine, only
minor improvements, tending to give greater durability and lighter draft were added.

The McCormick Light Steel Binder built in 1888[3]. This was an improvement over the first
steel binder of 1885[3]. The knotter was improved for the first time since the binder came into
existence. Improvements in the reel construction were made and an adjustable canvas grain
shield was added on the rear of the platform.
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The McCormick-Deering Tractor Binder is operated from the Formal tractor through the shaft
running out of the rear, thus making the binder independent of ground conditions. This power
take-off, as it is called, is regularly supplied with all Formal tractors. The binder, being
independent of ground conditions, can operate when a horse-drawn binder would find it
difficult, if not impossible, to cut grain.
Figure2.12. McCormick-Deering Tractor Binder

McCormick-Deering Harvester-Thresher is the most modern type of grain-harvesting
machine. It cuts 40-50 acres per day and threshes the grain, delivering it after a thorough
cleaning, into a grain tank. From the tank, the grain can be drawn off into a motor truck or
wagon and hauled to the grainer.
Figure2.13. McCormick-Deering Harvester-Thresher

This Windrow-Harvester cuts grain and leaves it in a windrow on top of the stubble. After the
grain cures on the stubble, it is picked up by an attachment on the platform and threshed. The
windrow-harvester makes it possible to cut grain earlier (avoiding natural hazards such as
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winds and hails) and to better harvest woody grain (because the weeds dry out with the crops
before threshing).
Figure2.14. The Windrow-Harvester
2.1.5. Riding Type Self- Propelled Reaper

The riding type vertical conveyor reaper is a self-propelled unit in which the operator rides on
the machine. Drive is given by means of two large pneumatic wheels and steering is by rear
idlers. The prime mover is a 6hp/4.5 kW diesel engine. Convenient clutch, break, steering,
hydraulic system and simple power transmission are provided for ease of operation. It consists of
crop row divider star wheel cutter bar (76.2 mm), conveyor belt and wire spring etc. This reaper
has two forward and one reverse speed. The crop after being cut is dropped in a windrow on the
side[ ].
Figure2.15. Riding type self- propelled reaper

2.1.6. Self- Propelled Vertical Conveyor Reaper
It is an engine operated, walk behind type harvester suitable for harvesting and windrowing
cereals and oilseed crops. The reaper consists of engine, power transmission box, pneumatic
wheels, cutter bar, crop row dividers, conveyor belts with lugs, star wheels, operating controls
and a sturdy frame. The engine power is transmitted to cutter bar and conveyor belts through
belt pulleys. During forward motion of the reaper, crop row dividers divide the crop, which
come in contact with cutter bar, where shearing of crop stems takes place. The cut crop is
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conveyed to one side of the machine by the conveyor belt fitted with lugs and is windrowed in
the field. The crop is bundled manually and transported to threshing yard[ ].
Figure2.16. Self- propelled vertical conveyor reaper
2.1.7. Self-Propelled Reaper Binder

Reaper-Binder is a unique harvesting machine that reaps the crop as well as binds it
simultaneously with a twine. This Innovative Mechanical machine ensures 100% recovery of
straw with negligible grain losses at a surprisingly low cost of operation. This machine is
mainly used in Wheat, Paddy, Oats, Barley and other grain crops[ ].
Figure2.17. Self-propelled reaper binder
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CHAPTER THERE
METHODOLOGY
To conduct the design of the wheat cutter machine the processes follows the product design
development (PDD) process.
Collecting data is done on existing parts of Tigray and Ethiopia areas; this information was
gathered from Mekelle university agriculture department and Supervision Enterprise and Tigray
agriculture Resource. The final design is the output of data inputs, conceptual design, and
analytic design. Data collection was through informal interviews, different design books and
from the internet. The final drawing is to be prepared using CATIAV5 software.
Farther more, the necessary thing is examine the cost estimation of the wheat crop cutter
machine by taking some information standard markets to know the cost of crop cutter component
and depending on the manufacturing process, assembly process, labor cost etc…After taking and
collecting some necessarily information for thesis project, process and analysis of that’s
information has done. Data collection was done through the two basic ways.
Primary Data: -
 Direct observation,
 Formal & informal interview with different professionals and from written data.
Secondary Data: -
 Different research works and wheat crop cutter manufacturers
 From internet.
Generally, after collecting the data by primary and secondary source, the process follows through
PDD sequence and procedure from identifying customer need, design analysis and cost
estimation. The methodology process follows PDD procedure as:
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Data collection method
Identify customer need
Establish target
specification
Generate product concept
Select product concept
Design analysis
Cost estimation
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CHAPTER FOUR
DESIGN CONCEPTS AND SELECTION
4.1. Concept Development Process
4.1.1. Identifying Opportunity
The opportunity is the problem, which is lack of wheat crop-cutter machine, so the Ethiopian
farmers tend to harvest the wheat crop with a nickel by consuming a lot of time, capital and
money.
4.1.2. Identifying Company Need
In ethiopia tigray region most of the farmers use traditional tools to cut the wheat crop in order to
harvest, so most of the Ethiopian farmers need a machine that can minimize the total cost, time
and labor, which have an overall profit.
4.1.3. Organizing Raw Data
The needs that obtained by direct observation and interview. The needs are organized as follows:
 Less number of components  Durability
 Design simplicity  Complexity
 Cost  Weight
 Strength  Operability
 Availability  Reliability
 Manufacturability  Maintainability
Preparing relative importance of needs
Table4.1. Preparing relative importance of needs
Product design needs Level of importance

Less number of components 3
Light weight 10
Low cost 1
Easy to operate and maintain 2
Safe and reliable 4
Strength 9
Design simplicity 6
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Durability 8
Availability 5
Manufacturability 7
4.2. Conceptual Design
Concept generation is when a product development team comes up with the ideas, is the most
critical step in the engineering design process, without it there is no design. It is the process of
creating, developing, communicating ideas, which are abstract, concrete or visual. The process
includes the process of constructing through the idea innovating the concept, developing the
process and bringing a concept to reality.
Different alternatives of crop cutting machine design
Hence, the following are some of the competitive mechanisms anticipated to meet the quality
and feature needed.
4.2.1. Model A: Design of manually operated crop cutting machine with engine as power source
to the machine and that uses chain sprocket and motorcycle chain with collecting plates welded
on it as collecting mechanism.
Figure4.1. Manually operated crop-cutting machine with engine as power source to the machine
Working Mechanism
This machine consists of two mechanisms one is a four bar mechanism for reciprocation
of cutter blade over stationary cutter blade and this mechanism is used to convert rotary
motion into linear motion. Second is collecting mechanism which consist chain sprocket
and motorcycle chain. This machine is powered by petrol engine. By using V-Belt power is
transmitted to bevel gear box. Bevel gear box is used to change direction of drive by
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in the gear system. One end of this output shaft is connected to four bar mechanism
which converts rotary motion of shaft into reciprocating motion of cutter blade.
Reciprocating cutter blade slides over fixed blade and creates scissoring action responsible
for cutting the crop.
Table4.2. Material selection for Model A
Number Components Material
1 Frame Mild Steel
2 V-Belt rubber fabric
3 Pulley cast iron
4 Shaft Mild steel
5 Key mild steel
6 Bevel gear AISI 1050 heat treated (hot rolled) steel
7 Blade /Cutter Stainless Steel
10 Bolts Carbon steel with grade 40C8
11 Nut Bronze
12 Handles Mild Steel
13 Chain High carbon steel
4.2.2. Model B:
Design of manually operated crop cutting machine with electric motor as power source to the
machine and that uses flat belt with collecting plates bolted on it as collecting mechanism.
Figure4.2. Manually operated crop-cutting machine powered with electric motor
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Working Mechanism
This machine is powered by electric motor. With the help of V-belt, drive power is transmitted to
gearbox. To reduce the speed of electric motor (to have suitable speed of the cutter), a spur
gearbox used. One end of this output shaft is connected to slider crank mechanism which
converts rotary motion of shaft into reciprocating motion of cutter blade. Reciprocating cutter
blade slides over fixed blade and creates scissoring action responsible for cutting the crops.
Collecting mechanism consist of flat belt with collecting plates bolted on it.
Table4.3. Material selection for Model B

1 Frame Mild Steel
3 Pulley cast iron
4 Shaft Mild steel
5 Key mild steel
6 Spur gear Carbon steel
9 Nut Bronze
11 Flat Belt for collecting mechanism Leather
12 Crop divider G.I. sheet
13 Roller Aluminium bronze
2010 E.C Page 17

4.2.3. Model C: Design of manually operated crop cutting machine with solar as power source to
the machine and that uses conveyor belt and reel mechanism as collecting mechanism.
Figure4.3. Manually operated crop-cutting machine with solar system as power source to the
machine
Working Mechanism
This machine is powered by solar energy connected to the battery and motor of the crop-cutter
machine. By using V-Belt and pulley, power is transmitted to shaft, and then as the shaft rotates
it will rotate the bevel gear and the two small pulleys. Bevel gear box is used to change direction
of drive by in the gear system and the two small pulleys are used for collecting mechanism.
The output shaft is connected to slider crank mechanism that converts rotary motion of shaft into
reciprocating motion of cutter blade. Reciprocating cutter blade slides over fixed blade and
creates Scissoring action responsible for cutting the crop. Collecting mechanism consist of
conveyor belt and reel mechanism which is powered by solar panels that is as the reel
Mechanism rotates it pushes the crop to the conveyor belt and goes to the collecting box.
Table4.4. Material selection for Model C

1 Frame Mild Steel
3 Pulley cast iron
4 Shaft: Mild steel
1)Rotating pulley shafts
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2)shafts that connected with slider

crank mechanism
5 Key mild steel
8 Conveyor Belt Cotton or Fabric/flat belt
9 Collecting box Mild steel
11 Nut Bronze
13 Reel Mechanism Mild Steel
14 Roller Mild Steel
4.2.4. Model D: Design of manually operated crop cutting machine with two-stroke engine as
power source to the machine and that uses conveyor belt and reel mechanism as collecting
mechanism.
Figure4.4. Manually operated crop-cutting machine that has two stroke engine (small engine) as
power source to the machine
Working Mechanism
2010 E.C Page 19

This machine is powered by two stroke engine (small engine). By using V-Belt and pulley,
power is transmitted to shaft, and then as the shaft rotates it will rotate the bevel gear and the two
small pulleys. Bevel gear box is used to change direction of drive by in the gear system and
the two small pulleys are used for collecting mechanism. The output shaft is connected to slider
crank mechanism that converts rotary motion of shaft into reciprocating motion of cutter blade.
Reciprocating cutter blade slides over fixed blade and creates Scissoring action responsible for
cutting the crop. Collecting mechanism consist of conveyor belt and reel mechanism which is
powered by two stroke engine (small engine) i.e. as the reel Mechanism rotates it pushes the crop
to the conveyor belt and goes to the collecting box. .
Table4.5. Material selection for Model D

1 Frame Mild Steel
3 Pulley cast iron
4 Shaft: Mild steel
1)Rotating pulley shafts
2)shafts that connected with slider
crank mechanism
5 Key mild steel
8 Conveyor Belt Cotton or Fabric/flat belt
9 Collecting box Mild steel
11 Nut Bronze
13 Reel Mechanism Mild Steel
14 Roller Mild Steel
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4.3. Design Matrix

This is a system of finding good alternatives among many model solutions for a particular
problem. There are different types of Design Matrices that are used to make systematic decisions
on choosing best alternatives of given two or more alternative designs. The following method is
selected so that to help reach at the best decision. This method has been adopted to meet the case
of the reaper. Besides, the functional requirements or weights are selected to suit to expectation
to physical, mechanical and environmental fitness of the reaper. Generally, there are four basic
alternatives investigated so far concerning the walking reaper in general.
Key
 very poor, very small, very few, very difficult,
 poor, small, few, low, difficult
 acceptable, average, normal
 good, high, large, possible
 excellent, very high
4.4. Concept Selection
Selection is a process of evaluating concepts with respect to customer needs and other criteria,
comparing the relative strengths and weaknesses of the concepts and selection of one or more for
further investigation, testing or development there for we are going to use the following
techniques:
 concept screening
 concept scoring
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Concept Screening
Table4.6. Concept screening
Number Selection criteria A B C D
1 Physical requirement
Less number of components + + - -
Complexity + + - 0
Weight - - - -
Operability - - + +
2 Mechanical requirement
Reliability - - + +
Durability 0 0 0 +
Effectiveness - - - +
Design simplicity 0 0 - -
3 Material requirement
Material cost 0 0 - -
Strength - - 0 +
Availability + + + +
Manufacturability 0 0 0 +
Maintainability - 0 - +
Number of plus 3 3 3 8
Number of minus 6 5 7 4
Number of same 4 5 3 1
Net -3 -2 -4 4
Rank No Yes No Yes
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Concept Scoring Matrix
Table4.7. Concept scoring matrix
Concept B Concept D
Selection criteria Weight (%) Rating Weighted Rating Weighted
score score
Less number of components 10 3 0.3 3 0.3
Complexity 10 3 0.3 3 0.3
Weight 5 2 0.1 3 0.15
Operability 10 3 0.3 4 0.4
Reliability 10 4 0.4 5 0.5
Durability 5 4 0.2 5 0.25
Effectiveness 10 3 0.3 5 0.5
Design simplicity 5 3 0.15 4 0.2
Material cost 10 2 0.2 3 0.3
Strength 5 4 0.2 4 0.2
Availability 10 3 0.3 3 0.3
Manufacturability 5 2 0.1 4 0.2
Maintainability 5 2 0.1 4 0.2
Total score 2.95 3.8
Rank 2 1
Continue No Develop
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CHAPTER FIVE
DESIGN ANALYSIS
Factors affecting performance of harvesting machines:
1. Crop Factors
 Crop variety
 Ambient temperature
 Maturity of crop
 Crop moisture
 Crop condition
 Crop density
2. Machine factors
 Shape and size of crop divider
 Reel position and speed
 Cutting blade shape and speed
 Conveyor speed
 Machine vibrations
 Machine settings
3. Operational Factors
 Height of cut
 Operation speed
N.B. Benefits for harvesting wheat within 20-14% moisture content[ ]
 High test weight
 Good seed germination
 Undamaged kernels if machine properly adjusted
 Cutter bar loss is less
 Rack and shoe loss are minimum
Input Parameters
 Pushing or driving force of human 150-200N
 8 working hours per day
 Average height of wheat crop is 700mm.
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 Diameter of wheat 3mm.

5.1. Selection of Two Stroke Engine and Determining of Capacity of Cutter
General assumptions and considerations
After carful assessment and analysis of different literatures, we have finally come to some
decisions.
 Cutting height= 10mm
 Output speed of 120rpm is assumed at maximum
 The strongest crop in which the wheat crop-cutting machine is supposed to cut is wheat.
 The forward velocity of the machine in km/h is 2 km/h
 The cutting width(length) of the machine is 1200mm
 The linear density of the wheat crop stem is 0.79 ⁄
 The wheat crop stand density in number/ is 400 /
Table5.1. Shear strength of wheat straw with the blade (Mpa)
Moisture content % Shearing strength of straw

15 3.25
25 3.57
35 3.69
45 3.86
( )
Where: T=cutter head torque
F=is the shearing force
r=length of the cutter
Where: τ is shear strength of the material to be cut=3.25MPa

( )
A is cross-sectional area of wheat crop= =7.065
( ) ( )
Power required for the crop cutting
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Feeder Conveyor
The crop mass delivered by platform conveyor is transferred to collecting box by feeder
conveyor. Generally, power is consumed for conveying the wheat crop is
Figure5.1. Wheat crop passing through feeder conveyer

( )
Where
F=is the crop feed rate in Mg/h
Is the crop stand density in number/
Is the forward velocity of the machine in km/hr.
= is the linear density of the crop stem in g/m
w=is the cutting width of the machine in m
h=is the crop height, m
=is the height of cut in m
( )
That is the same with the power to reel the crop=
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Total power required to operate the crop-cutting machine is
Note: The service factor for this type of machine is from 1 to 1.4.
Now from table of standards let’s use power = 0.75kw
Table5.2. Two stroke engine selection
Engine Displac Rated speed Fuel Model No Spindle Feature Weight Fuel
power ement (Speed tank size . mixture
Controllable
(rpm))
0.75kw 24.5cc 915 0.4L EM2500U M8 x Waist 15kg 50 : 1
1.25LH Cushio
n
Capacity of the Machine
Volume flow rate per cutter
⁄ ⁄
Total volume flow rate
Density of wheat
Total mass flow rate of wheat is
Therefore the capacity per second is,
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5.2. Design of V- Belt and V-Grooved Pulley

A belt or chain drive provides a convenient means for transferring motion from one shaft to
another by means of a belt or chain connecting pulleys on the shafts.
In many cases, their use reduces vibration and shock transmission, simplifies the design of a
machine substantially, and reduces the cost.
Figure5.2. V-belt and V-grooved pulley cross-section

Specifications and Assumptions
Design power,
Input engine speed,
Output speed,
Pulley groove angle,
Material Selection
Material for belt is rubber fabric, ⁄
Allowable tensile stress of belt, ⁄
Material for pulley is cast iron due to low cost, ⁄
Coefficient of friction between belt and pulley (A textbook of machine design by R.S.
Khurmi and J.K. Gupta page 681)
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Required
 Dimensions of V-belt and pulleys
 Number of belt
Figure5.3. Belt
Analysis
Determine the speed (velocity) ratio,
The minimum pulley diameter for the given engine power is given in the following standard
table.
Table5.3. Properties of V belt (IS 2494:1974)
Belt Power ranges Minimum pitch Width of Thickness Area of belt

type in Kw diameter of pulley belt (b) in of belt(t) in
D in mm mm in mm
A 0.75-3.5 75 13 8 0.81
B 2-15 125 17 11 1.41
C 7.5-75 200 22 14 2.3
For 0.75kw power the diameter of pulley mounted on the engine A type of belt should be used,
, width of the belt , and
( )
Where slip, s= 0.02
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Note: sometimes, the frictional grip between the pulley and belt becomes insufficient.
This may cause some forward motion of the driver without carrying the belt with it. This is
called slip of the belt and is generally expressed as a percentage. The result of the belt slipping is
to reduce the velocity ratio of the system.
Figure5.4. Forces on a moving belt

The friction force on the belt is taken to be uniform throughout the entire arc of contact. Due to
friction of the rotation of the driver pulley, the tight-side tension is greater than the slack-side
tension.
Center-to-center distance, c is given such that
( )
Hence, c is between 224.175mm and 897.525mm
Now let
Angle of lap or contact on the smaller pulley:
Note: the smaller value of for the pulley will governs the design,
Angle of lap or contact on the larger pulley:
Length of the belt:
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√ ( ) ( )
√ ( ) ( )
Centrifugal tension of belt,
,
Where
( )
Maximum tension in the belt,
Tension in the tight side of the belt,
Let is the slack-side tension
From this we get,
The power transmitted per belt ( ) ( )
Number of V-belts, z
Had we been used a single belt, the tensions on the tight and slack would have been doubled. i.e.
( )
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Standard dimensions of V grooved pulleys
Figure5.5. Cross-section of V-grooved pulley
Table5.4. Dimensions of standard V-grooved pulleys according to IS: 2494–1974.
Type of W D A C F E No of Groove angle (2 )

belt sheaves in degres
A 11 12 3.3 8.7 10 15 6 32, 34, 38
B 14 15 4.2 10.8 12.5 19 9 32, 34, 38
C 19 20 5.7 14.3 17 25.5 14 34, 36, 38
D 27 28 8.1 19.9 24 37 14 34, 36, 38
E 32 33 9.6 23.4 29 44.5 20 -
Note: Face width, ( ) , where

From the above table w=11mm, d= 12mm, a = 3.3mm, c =8.7mm, f = 10mm and e =15mm
Face width, ( ) ( )
Note: The number of arms may be taken as 4 for pulley diameter from 200 mm to 600 mm and 6
for diameter from 600 mm to 1500 mm. The pulleys less than 200 mm diameter are made with
solid disc instead of arms.
5.3. Design of Bevel Gear
Definition of Gears
Gears are toothed members, which transmit power motion between two shafts by meshing
without any slip. Hence, gear drives are also called positive drives. In any pair of gears, the
2010 E.C Page 32

smaller one is called pinion and the larger one is called gear immaterial of which is driving the
other.
The following are the advantages of the gear drive as compared to other drives, i.e. belt, rope and
chain drives:
Advantages
1. It transmits exact velocity ratio.
2. It may be used to transmit large power.
3. It may be used for small center distances of shafts.
4. It has high efficiency.
5. It has reliable service.
6. It has compact layout.
Standard Proportions of Gear Systems
Table5.5. Standard proportions in module (m) for the four gear systems.
S. No. Particulars 14.5 composite full depth 20 full depth 20 stub

involute system involute involute
system system
1 Addendum 1m 1m 0.8m
2 Dedendum 1.25m 1.25m 1m
3 Working depth 2m 2m 1.6m
4 Minimum depth 2.25m 2.25m 1.8m
5 Tooth thickness 1.5708m 1.5708m 1.5708m
6 Minimum 0.25m 0.25m 0.25m
clearance
7 Fillet radius at 0.4m 0.4m 0.4m
root
Specifications and Assumptions
Design power,
Output speed (gear speed),
Input speed (pinion speed),
Pressure angle
2010 E.C Page 33
Number of teeth of the pinion=18(A textbook of machine design by R.S. Khurmi and J.K. Gupta
page 1034, table28.2)
The face width = ⁄ of slant height of pitch cone.
Factor of safety
Material Selection
AISI 1050 heat treated (hot rolled) steel having
Ultimate tensile strength
Modulus of elasticity E =207Gpa
Brinell hardness ( ) =514
Analysis
Velocity ratio will be
Therefore the number of teeth on the gear is,
Since the shafts are at the right angle, therefore pitch angle for the pinion,
( ) ( )
The pitch angle for the gear is,
The formative number of teeth for pinion is,
The formative number of teeth for gear is,
Tooth form factor for the pinion is,
Tooth form factor for the gear is,
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Since the allowable static stress for both the pinion and gear is the same and is less than
therefore the pinion is weaker. Thus the design should be based upon the pinion.
The torque on the pinion is,
The tangential load on the pinion is,
The pitch line velocity is,
Allowable working stress (Allowable dynamic stress) is,
( ) ( )
The length of the pitch cone element or slant height of the pitch cone is,
The face width is,
The tangential load on the pinion is,
( ) ( )
( ) ( )
Solving this expression by hit and trial method, we find that
The face width is
2010 E.C Page 35

Addendum (a) and Dedendum (d) is,
Working depth=2m=6mm
Minimum depth=2.25m=6.75mm
Tooth thickness=1.5708m=4.71mm
Minimum clearance=0.25m=0.75mm
Fillet radius at root=0.4m=1.2mm
Slant height of the pitch cone (L) =
Outer diameter for the pinion is,
Pitch circle diameter for the pinion is,
Outer diameter for the pinion is,
Pitch circle diameter for the gear is,
Check for the Dynamic Load

( )
√
⁄ ⁄
For A textbook of machine design by R.S. Khurmi and J.K. Gupta page 1041, we have K=0.111
and from table 28.7 we have the tooth error action (e)=0.025
Deformation or dynamic factor,
2010 E.C Page 36

( )
√
The flexural endurance limit for steel is 126MPa (For A textbook of machine design by R.S.
Khurmi and J.K. Gupta, table28.8)
The endurance strength of the tooth is,
From above we see that , therefore the design is satisfactory, from the
standpoint of dynamic load.
5.4. Design of Shaft
A shaft is a rotating member, usually of circular cross section, used to transmit power or motion.
It provides the axis of rotation, or oscillation, of elements such as gears, pulleys, flywheels,
cranks, sprockets, and the like and controls the geometry of their motion. However, a shaft can
have a noncircular cross section and need not be rotating. An axle, a nonrotating member that
carries no torque, is used to support rotating members.
Figure5.6. Shaft
Material Selection
Mild steel is general-purpose steel bars for machining, suitable for lightly stressed components
including studs, bolts, gears, handles and shafts.
It is less costly.
Mechanical Properties
2010 E.C Page 37

Yield strength
Density,
Given Parameters and Assumptions

Design power,
Shaft speed,
Safety factor, F.s=2.5 (assume)
Diameter of smaller pulley
Diameter bigger pulley,
Tension on tight side of the belt,
Tension on slack side of belt,
Required
 Diameter of shaft,
Analysis
The shaft is subjected to torque of,
Vertical load acting on the shaft at C
Horizontal load acting on the shaft at A
2010 E.C Page 38

Vertical load acting on the shaft at F
Vertical load acting on the shaft at D is,

Tangential force on the gear is,
The normal load acting on the tooth of the gear is,
Where D= Pitch circle diameter for the pinion

Pressure angle
To find the vertical reaction on the bearing we use the force and moment equilibrium equation
∑F = 0, = 1369.499N
∑MB = 0 we have
In similar manner to the above

∑F = 0, = 214.44N
∑MB = 0 we have
We know that B.M at B and E is zero.

The bending moment in the vertical loading is,
B.M at A,
B.M at C,
B.M at D,
B.M at F,
The bending moment in the horizontal loading is,
B.M at A,
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B.M at C,
B.M at F,
The resultant B.M is,
√( ) ( )
The resultant B.M for A,
The resultant B.M for C,
The resultant B.M for D,
The resultant B.M for F,
The maximum bending moment is at D.
Equivalent twisting moment

√( )
Where, = Combined shock and fatigue factor for bending, and
= Combined shock and fatigue factor for torsion.
Table5.6. Recommended values for Km and Kt.
Nature of load
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 1.5 to 2.0 1.5 to 2.0
shocks only
Now for suddenly applied load with minor shocks only
√( ) ( )
Again, Diameter of shaft
2010 E.C Page 40

( )
According to maximum shear stress theory,
Therefore
( )
Equivalent bending moment

( √( )
( √( )
According maximum normal stress theory,
Now taking the maximum
5.5. Design of Key

A key is a piece of mild steel inserted between the shaft and hub or boss of the gear to connect
these together in order to prevent relative motion between them.
Figure5.7. Key
2010 E.C Page 41

Material Selection
The same material as the shaft
 Torque provided by shaft =
 Factor of safety =2.5 (assume)
 Diameter of shaft d=40mm
 Allowable shear stress
 Allowable crushing stress
Required
 Dimensions of the key.
Analysis
From table of standards we find that for a shaft of 40 mm diameter,
Table5.7. Proportions of standard parallel tapered and gib head keys.
Shaft Key cross-section Shaft Key cross-section

diameter(mm) up Width Thickness(mm) diameter(mm) Width Thickness(mm)
to and including (mm) up to and (mm)
including
22 8 7 170 45 25
30 10 8 200 50 28
38 12 8 230 56 32
44 14 9 260 63 32
Source (a textbook machine design by R.S. KHURMI&J.K. GUPTA page 472)
Let’s take the width and thickness the same shaft diameter 44mm. then width of key, w = 14 mm
and thickness of key, t = 9 mm
The length of key is obtained by considering the key in shearing and crushing.
Let l = Length of key.
Considering shearing of the key, we know that shearing strength of the key,
Now
2010 E.C Page 42

Considering the failure of key due to crushing,
Now,
Taking the larger of the two values, we have since the face with of the pulley is
35mm.
The key has taper 1 in 100 on the top side only.
5.6. Design and Selection of Contact Ball Bearing
A bearing is a machine element that supports another moving machine element (known as
journal). It permits are relative motion between the contact surfaces of the members, while
carrying the load.
Rating Life:
Rating life is defined as the life of a group of apparently identical ball or roller bearings, in
number of revolutions or hours, rotating at a given speed, so that 90% of the bearings will
complete or exceed before any indication of failure occur.
Figure5.8. Bearing
Shaft speed,
The shaft diameter is 40mm
The bearing is subjected to radial load,
√( ) √( )
The machine is to be used approximately 8 hrs. Per day

The average service life of 5 years
2010 E.C Page 43

200 working day per year

Analysis
Total working hours of the machine = 5×200×8= 8000hrs
Life in millions of revolution for the bearing
Most manufacturers specifies dynamic load rating C which is load that results in cycle (one
million cycles).
Equivalent radial load
X and Y are factors determined from table

V = 1, when inner ring rotates
=1.2, when outer ring rotates
is axial component of the force acting on the bearing = 0 in this case
Table5.8. Equivalent Radial Load Factors for Ball Bearings
⁄( ) ⁄( )
⁄ E
0.014 0.19 1.00 0 0.56 2.30

0.021 0.21 1.00 0 0.56 2.15
0.028 0.22 1.00 0 0.56 1.99
0.042 0.24 1.00 0 0.56 1.85
Basic or dynamic load rating
( )
L: life in millions of revolution or life in hours
a: constant which is 3 for ball bearings and 10/3 for roller bearings
( ) ( )
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Now, the table 9.9 below for single row deep groove ball bearing shows that for a 40mm inner
diameter, the value of . Therefore, this bearing may be selected safely for the given
requirement without increasing the shaft size.
Table5.9. Dimensions and Load Ratings for Single-Row 02-Series Deep-Groove and Angular-
Contact Ball Bearings
Shoulder Load ratings, Kn

diameter, mm Deep Angular contact
groove
Bore, OD, Width, Fillet
Mm mm Mm radius,
mm
30 62 16 1.0 35 55 19.5 10.0 20.3 11.0
35 72 17 1.0 41 65 25.5 13.7 27.0 15.0
40 80 18 1.0 46 72 30.7 16.6 31.9 18.6
45 85 19 1.0 52 77 33.2 18.6 35.8 21.2
We shall denote the catalog load rating as . The catalog load rating is often referred to as a
Basic Dynamic Load Rating, or sometimes-just Basic Load Rating, if the manufacturer’s rating
life is 106 revolutions. Source (Shigley's Mechanical Engineering Design (9th edition, Budynas,
Nisbett) page 581)
Bore =40mm
Outside diameter =80mm
Width=18mm
5.7. Design of Reel
Input data
Deflection angle
Reel radius R = 20 cm
Reel rotational speed 40 rpm
Analysis
Rotational velocity of the reel
2010 E.C Page 45
Peripheral speed of the reel

⁄ ⁄
Forward speed of the machine
Reel speed index is defined as the ratio of reel peripheral speed to forward travel speed and is
typically 1.25 to 1.5 under most conditions in upright crops.( Ephrem Zeleke, October 2012)
⁄ ⁄ ⁄
Distance whose magnitude is equal to header advance per radian of reel rotation,
⁄ ⁄
⁄
⁄
Figure5.9. Angular displacement of two successive tine bars

Reel stagger
( )
( )
Angular displacement between successive tine bars calculated as,
( )
( )
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The number of tine bars on the reel n
5.8. Selection of Wheat Crop Cutting Blade

It is very strong, made of sharp scissors with teeth, and is used to cut the crop down.
Figure5.10. Cutting blade
Table5.10. Specification of cutter blade
Crop cutting unit

1 Type of cutter bar Reciprocating knife
2 Length of cutter bar 100 mm
3 Knife section Standard
4 Type Trapezoidal
5 Blade Serrated
6 Angle between cutting edge and axis of knife section 30º
(α)
7 Rake angle 22º
8 Thickness of cutting edge 5-3 mm
9 Material High carbon steel
10 Mass 0.28kg
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5.9. Capacity and Dimension of the Belt Conveyor

Let r1= radius of driver drum
r2=radius of follower drum
x=distance between center of two drums
L=total length of belt
Figure5.11. Conveyor
We know that
L=arc of driver + length of slack side + arc of follower + length of tight side
X = 1.2 meter the actual distance from center to center distance of the drum of the conveyor.
However, the diameter of drums available in our second hand store is 0.2m i.e. radius=0.1m
Therefore, the dimension of the conveyor is assumed to be W=0.7m and total length of 3.028m.
Capacity of belt conveyor of the wheat crop-cutter machine can be calculated as:
Capacity = load cross sectional area (m2) * belt speed (m/s) * material density (kg/m3)
2010 E.C Page 48

( ) ⁄ ⁄
⁄
Therefore, the material of the belt is oak tanned leather belt on the stainless steel drum.
5.10. Design of Vertical Frame (Columns and Beam)
A column is a structural member that carries an axial compressive load of the machines and that
tends to fail by elastic instability, or buckling, rather than by crushing the material.
The tendency for a column to buckle is dependent on the shape and the dimensions of its cross
section, along with its length and the manner of attachment to adjacent members or supports.
There are four types of end conditions
1. Both the ends hinged or pin jointed
2. Both the ends fixed
3. One end is fixed and the other hinged
4. One end is fixed and the other free
Therefore, in our case as we visualize the columns from the assembly drawing it is
Fixed at both ends
Beam is horizontal structure that is used to support the components of the machine and the crops.
Material Selection
Mild steel
Yield strength
Density,
Factor of safety=2
The total weight to be supported is the summation the dead and live loads.
Calculations of dead weight of machine supported by column and beam
1. Weight of Bevel Gear
Material: AISI 1050 heat-treated (hot rolled)
Pressure angle on gear =20°
Number of teeth of the gear
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Face width
Module
Number of gears
Weight of the gears
2. Weight of Shaft
Material, mild steel
Density:
Diameter shaft
Length of shaft
Number of gears
Volume of the shaft
Mass of shaft
Weight of the shaft
3. Weight of Key
Material: mild steel
Density:
Length of key
Width of key
Thickness of key
Number of key
Volume of the key
Mass of key
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Weight of key
4. Weight of Cutter
Material, high Steel-carbon
Density:
Length of cutter
Number of cutter, n=12
Length of cutter (for single), l=100mm
Thickness of cutter,
Width of cutter
Volume of the cutter
Mass of cutter
Weight of the cutters
5. Weight of Two Stroke Engine

We have mass of an engine form specification which is 15kg.
6. Weight of Small Pulleys

Material: cast iron
Density:
Diameter
Face width
Diameter of shaft
Number of pulleys
2010 E.C Page 51

Figure5.12. Small pulley

Key way dimensions
Volume of the pulley
( ) ( )
Mass of pulley
Weight of small pulleys
7. Weight of Large Pulley

Material: cast iron
Density:
Diameter
Face width
Diameter shaft
Number of pulleys
Key way dimensions
Area of approximate rectangle

Volume of the pulley
2010 E.C Page 52

( ) ( )
Mass of pulley
Weight of pulley
8. Weight of Collecting Box (plate)

Density:
Thickness
Volume of the plate
Mass of plate
Weight of plates
9. Weight of Structural Frame

Density:
Hollow rectangular cross sections

Thickness
B=60mm
H=60mm
Total length of frame used
Volume of the frame

2010 E.C Page 53
[ ( ) ( )]
[ ( ) ( )]
Mass of frame
Weight of frame
Total dead load supported by columns
Assume the collecting box can carry 15kg of wheat at a time

Live weight of wheat
Total weight
Design of Column
L t
H B
Figure5.13. Column
Hollow rectangular cross sections
Thickness
B=60mm
H=60mm
2010 E.C Page 54

L=1000mm
Let
Table5.11. Relation between actual length (L) and effective length Le
No End conditions Relation between actual length ( ) and

effective length
1 Both ends pined
2 Both ends fixed
3 One end fixed and the other pined
4 One end fixed and the other free
Because both side are fixed
End fixity factor
is least moment of inertia for the columns cross-sectional area.

( )
Cross sectional area
Compute the slenderness ratio. The radius of the gyration must be computed the axis that gives
the least value. This is the y –axis for which
√ √
The transition slenderness ratio
Again the transitions slenderness ration for mild steel
2010 E.C Page 55

Then so the column is short
Johnson formula to compute the critical load

( )
( )
( )
(
( ) ( )( )
Critical stress
Since and , design is safe.
Design of Beam
w
1200mm
From above calculation we have total weight
⁄
Then summation of force in vertical plane will be
⁄
Then let’s determine the moment at point B. that is ∑

⁄
2010 E.C Page 56

Center axis is given by
Then let’s determine the allowable stress of the material
The bending stress ( ) is less than allowable stress (

). Then the design is safe.
5.11. Design of Scotch Yoke
The scotch yoke mechanism is widely used as a sine and cosine generator, i.e. it is used to
produce harmonic motion. It is also used to produce desired vibrations. It is also used reciprocate
the cutting blade to cut the crop (wheat).
Figure5.14. Scotch yoke

Input data
Output speed of shaft is 120rpm
Radius of Scotch yoke 100mm
Angle =
2010 E.C Page 57

Material Selection
Mild steel
Yield strength
Density,
Analysis
The displacement of the slider x is
( )
( )
The angular velocity is
⁄
The velocity of the follower is
⁄
⁄
And the acceleration is
( )
⁄
Its mass is given by
2010 E.C Page 58

Then the weight is
5.12. Design of Welding

A welded joint is a permanent joint which is obtained by the fusion of the edges of the two parts
to be joined together, with or without the application of pressure and a filler material.
The welding processes may be broadly classified into the following two groups:
1. Welding processes that use heat alone e.g. fusion welding.
2. Welding processes that use a combination of heat and pressure e.g. forge welding.
The fusion welding, according to the method of heat generated, may be classified as:
1. Thermit welding,
2. Gas welding and
3. Electric arc welding.
In electric arc welding, the filler metal is supplied by metal welding electrode.
Therefore, this type of welding is going to be used in this design.
Given parameters and assumptions
Figure5.15. Welded joint of frame

⁄
Eccentric load
2010 E.C Page 59

 Length of eccentricity
 Electrode material is made of bare electrode
 ( ) =0.8 due to decrease in strength of the material
during welding and the type of electrode we use somewhat is multiplied by a factor
 Fillet type of weld is used

When the parts are subjected to fatigue loading, the stress concentration factor as given in the
following table should be taken into account.
Table5.12. Stress concentration factor for welded joints
Type of joint Stress concentration factor

1. Reinforced butt welds 1.2
2. Toe of transverse fillet weld 1.5
3. End of parallel fillet weld 2.7
4. T-butt joint with sharp corner 2.0
Stress concentration factor can be taken 2.7
Required
 Size of the weld, s
Analysis
The weld is supposed to join parts of the frame and other components in the machine. The part
subjected to higher load governs the design.
 The joint will be subjected to direct shear stress due to shear force (P)
 The joint will be subjected to bending stress due to a bending moment
The throat area for square fillet weld,
( ) ( )
( )
Then the direct shear stress will be,
Also the bending moment will be,
2010 E.C Page 60

The section of modulus for square section will be,
( )
Then bending moment will be,
Table5.13. Stress for weld joints
Type of weld Stress(MPa)

1 Fillet welds 80
2 Butts welds
Tension 90
Compression 100
Shear 55
From maximum shear stress theory we have,
√( ) ( )
√( ⁄ ) ( ⁄ )
5.13. Wheel Selection

Total dead load supported by wheel
Assume the collecting box can carry 15kg of wheat at a time

Live weight of wheat
2010 E.C Page 61

Total weight
Table5.14.Wheel selection
SIZE CODE PRODUCT DIAMETER WIDTH RIM MAX MAX
WIDTH LOAD @ PSI
10 MPH
21x11.00-8 599044 21 10.8 8.50 1390 22
21x11.00-10 599050 20.9 10.4 8.50 1390 22
24x12.00-12 560352 24 12 9.50 1710 20
The wheel with size code 21x11.00-8 is selected.
2010 E.C Page 62

CHAPTER SIX
COST ESTIMATION
6.1. INTRODUCTION
Evaluating a set of feasible alternatives requires that costs should be analysed so that we can
estimate the cost of a product.
Cost estimation of a machine includes
a) Material cost
b) Direct labor cost
c) Overhead cost and others(machine cost and transportation cost)
Note: Manufacturing overhead costs include indirect materials and indirect labor costs like
materials used to support the production process and wages paid not directly involved in
production work.
Now we can calculate the cost the machine components as follows
1) Two Stroke Engine
Quantity = 1
Unit price = 18850birr
2) V-belt
Material; rubber
Quantity = 6
Unit price = 146.922 birr
Cost = 6×146.922 = 881.53 birr
3) Small Pulleys
Material; cast iron
Quantity = 3
Unit mass =
Unit price = 23.67 birr /kg
Material cost
Manufacturing process; Casting & machining
Direct labor cost/hour = 13 birr
Total hours required = 6 hours
2010 E.C Page 63

Total labor cost
Overhead cost/hour = 40 birr

Total overhead cost =
Total cost = Material cost + Total labor cost + total overhead cost = 55.387+234+720 = 1009.4
birr
4) Large Pulleys
Material; cast iron
Quantity = 3
Unit mass =
Material cost
Manufacturing process; Casting & machining
Total labor cost
Total cost = Material cost + Total labor cost + Overhead cost = 2034.43+234+720 = 1632.14 birr
5) Shaft
Material; Mild steel
Quantity = 3
Unit mass =
Material cost
Manufacturing process; Turning, &milling for key ways
2010 E.C Page 64

Direct labor cost/hour = 14.01 birr

Total labor cost
Total cost = Material cost + Total labor cost + Overhead cost = +252.2+126 = 1429.14
birr
6) Key
Material; Mild steel
Quantity = 7
Unit mass =
Material cost
Manufacturing process; Cutting and milling operations
Total hours required = 3.5 hours
Total labor cost
Total cost = Material cost + Total labor cost + Overhead cost = 38.32+245+122.5 = 372.97 birr
7) Bevel Gear
Material; AISI 1050 heat-treated (hot rolled)
Quantity = 1
Unit mass = 0.886kg
Unit price = 120 birr /kg
2010 E.C Page 65

Material cost
Manufacturing process; casting and finishing process
Total labor cost
8) Cutter Blade
Material; steel-carbon
Quantity = 12
Unit mass =
Unit price = 38 birr /kg
Material cost
Manufacturing process; Cutting and drilling operations
Overhead cost/hour = 12.5 birr
Total labor cost
9) Bearing
Quantity = 6
Total cost =
2010 E.C Page 66

10) Collecting Box (Plate)

Material; mild steel
Unit mass = 14.148kg
Material cost
Manufacturing process; Cutting and welding operations
Total labor cost
Total cost = Material cost + Total labor cost + Overhead cost =335+2.5+0.75 = 338.25 birr
11) Collecting Belt (Conveyer)
Quantity = 1
12) Wheel
Quantity = 4
Cost = 4×2150 = 8600birr
13) Scotch Yoke
Unit mass = 4.94kg
Material cost
Manufacturing process; Cutting and welding operations
2010 E.C Page 67

Total labor cost
Total cost = Material cost + Total labor cost + Overhead cost =116.97+2.5+0.75 = 120.23 birr
14) Frame
Quantity = 1
Unit mass = 21kg
Material cost
Manufacturing process; cutting to size, bending and welding
Total hours required = 1hour
Total labor cost
Total cost = Material cost + Total labor cost + Overhead cost =497.28+10+5 = 512.28birr
Total cost of the machine is
6.2. Result and Discussion

This wheat cutter machine for farmers improves the speed of harvesting. In addition, this system
reduces the human effort. The workers are eliminated and the ultimately the operation cost is
reduced and profit is increased. This system is beneficial and safety for the farmers. By
2010 E.C Page 68

observing the cause of failure to the different parts of the belt conveyor like shaft, column and
other parts
Table6.1. Result and discussion
Capacity of the wheat cutter machine 0.047kg/sec
Power supply 750W
Capacity of the conveyor 0.28g/sec
Speed of the conveyor 0.1m/sec
The cutting width 1200mm
Forward velocity of the machine 2km/hr
Cutting height 10mm
2010 E.C Page 69

CHAPTER SEVEN
CONCLUSION AND RECOMMENDATION
7.1. Conclusions
The focus of this project was to design a wheat crop-cutting machine under certain constraints
such as compact size, easy to operate, low cost etc. A model has been created within
prescribed boundaries to meet the demands of the farmer and to make harvesting more
flexible operation. Based on the models and analyses presented in the previous sections,
various conclusions can be drawn. A model with design capability 0.047 kg/sec, use 750 watt
(0.75kw) power and capacity of the conveyor is 0.28g/sec has been developed. Also a model,
which is easy to operate and manipulate, has been developed which can be used for efficient
harvesting of wheat crops. Small-scale farmers for increasing their profits by decreasing labor
and machinery cost can use the model so constructed. The model can be carried out with
affordable capacity of most of Ethiopians. And also a better quality product can be
produced. That in turn will save a huge amount of foreign currency which was paid to import
these huge machineries and able to provide the low farmers to use the machine in affordable
cost. This model will offer a better and inexpensive method to reduce man power and
efforts involved in harvesting wheat crops.
2010 E.C Page 70

7.2. Recommendation
The design capability of the wheat crop-cutter machine 0.047 kg/sec and the speed of the
machine must not exceed above measure therefore, I strongly recommend that the wheat cutter
machine must not loaded above the capacity and the wheat cutter machine is manually driven
therefore a man with a capacity of 150 up to 200N can move the machine in a straight level but if
the degree of elevation the machine move increased due to the weight of the machine the man
may not able to actuate it so it mostly recommended that the elevation should be straight.
I also recommend that Different parts of the wheat cutter machine like the connection between
nut and screw, between holder (bearing) and shaft, gears and other parts must be properly
lubricated and handled carefully.
2010 E.C Page 71

REFERENCES
1. Medic (1999). Survey of the Ethiopian Economy: Review of Post Reform
Developments1992/3-1997/8. Addis Ababa. Ministry of Economic Development and
Cooperation.
2. McCormick, c. (n.d.). mechanical reaping machine 1831.
3. Charles B. withington, “improvement grain-binders” U.S. patent
no123,967(issued:February 20, 1872)
4. Quick,graeme R.:wesley F. buchele(1978).the grain harvesters,st. joseph:american
society of agricultural engineers.ISBN 0-916150-13-5.
5. Harvesting machinery by Prof. Dr. Muhammad Iqbal, Department of Farm Machinery &
Power, University of Agriculture, Faisalabad
6. A text book of machine design 14th edition, R.S Khurmi and JK Gupta, Eurasia
publishing house (pvt. ltd) 2005.
7. Shigley's Mechanical Engineering Design (9th edition, Budynas, Nisbett).
8. Ephrem Zeleke (October, 2012). Design and Modification of Appropriate Reel
Mechanism to Harvest Tef Crop.
2010 E.C Page 72

APPENDIXES
Table5.1.Shear strength of wheat straw with the blade (Mpa)
Moisture content % Shearing strength of straw
15 3.25
25 3.57
35 3.69
45 3.86
Table5.2. Two stroke engine selection

Engine Displac Rated speed Fuel Model No Spindle Feature Weight Fuel
power ement (Speed tank size . mixture
Controllable
(rpm))
0.75kw 24.5cc 915 0.4L EM2500U M8 x Waist 15kg 50 : 1
1.25LH Cushio
n
Table5.3.Properties of V belt (IS 2494:1974)

Belt Power ranges Minimum pitch Width of Thickness Area of belt in
type in Kw diameter of pulley belt (b) in of belt(t)
D in mm mm in mm
A 0.75-3.5 75 13 8 0.81
B 2-15 125 17 11 1.41
C 7.5-75 200 22 14 2.3
D 20-150 335 32 19 4.75
E 30-350 500 38 23 6.95
2010 E.C Page 73

Table5.4.Dimensions of standard V-grooved pulleys according to IS: 2494–1974.

Type of w D A C F E No of Groove angle (2 ) in
belt sheaves degres
A 11 12 3.3 8.7 10 15 6 32, 34, 38
B 14 15 4.2 10.8 12.5 19 9 32, 34, 38
C 19 20 5.7 14.3 17 25.5 14 34, 36, 38
D 27 28 8.1 19.9 24 37 14 34, 36, 38
E 32 33 9.6 23.4 29 44.5 20 -
Table5.5.Standard proportions in module (m) for the four gear systems.

S. No. Particulars 14.5 composite full depth 20 full depth 20 stub
involute system involute involute
system system
1 Addendum 1m 1m 0.8m
2 Dedendum 1.25m 1.25m 1m
3 Working depth 2m 2m 1.6m
4 Minimum depth 2.25m 2.25m 1.8m
5 Tooth thickness 1.5708m 1.5708m 1.5708m
6 Minimum 0.25m 0.25m 0.25m
clearance
7 Fillet radius at 0.4m 0.4m 0.4m
root
2010 E.C Page 74

Table4.1. Recommended values for Km and Kt.

Nature of load
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 1.5 to 2.0 1.5 to 2.0
shocks only
(c) suddenly applied load with heavy 2.0 to 3.0 1.5 to 3.0
shocks
Table5.7.Proportions of standard parallel tapered and gib head keys.

Shaft Key cross-section Shaft Key cross-section
diameter(mm) up Width Thickness(mm) diameter(mm) Width Thickness(mm)
to and including (mm) up to and (mm)
including
22 8 7 170 45 25
30 10 8 200 50 28
38 12 8 230 56 32
44 14 9 260 63 32
50 16 10 290 70 36
Table5.8. Equivalent Radial Load Factors for Ball Bearings
⁄( ) ⁄( )
2010 E.C Page 75

⁄ E
0.014 0.19 1.00 0 0.56 2.30

0.021 0.21 1.00 0 0.56 2.15
0.028 0.22 1.00 0 0.56 1.99
0.042 0.24 1.00 0 0.56 1.85
Table 5.9.Dimensions and Load Ratings for Single-Row 02-Series Deep-Groove and Angular-
Contact Ball Bearings
Shoulder Load ratings, Kn
diameter, mm Deep Angular contact
groove
Bore, OD, Width, Fillet
Mm Mm Mm radius,
Mm
30 62 16 1.0 35 55 19.5 10.0 20.3 11.0
35 72 17 1.0 41 65 25.5 13.7 27.0 15.0
40 80 18 1.0 46 72 30.7 16.6 31.9 18.6
45 85 19 1.0 52 77 33.2 18.6 35.8 21.2
Table5.10. Specification of cutter blade
Crop cutting unit
1 Type of cutter bar Reciprocating knife
2 Length of cutter bar 100 mm
3 Knife section Standard
4 Type Trapezoidal
5 Blade Serrated
6 Angle between cutting edge and axis of knife section 30º
(α)
7 Rake angle 22º
2010 E.C Page 76

8 Thickness of cutting edge 5-3 mm

9 Material High carbon steel
Table5.11. Relation between actual length (L) and effective length Le

No End conditions Relation between actual length ( ) and
effective length
1 Both ends pined
2 Both ends fixed
3 One end fixed and the other pined
4 One end fixed and the other free
Table5.12.Stress concentration factor for welded joints

Type of joint Stress concentration factor
1. Reinforced butt welds 1.2
2. Toe of transverse fillet weld 1.5
3. End of parallel fillet weld 2.7
4. T-butt joint with sharp corner 2.0
Table5.13.Stress for weld joints

Type of weld Stress(MPa)
1 Fillet welds 80
2 Butts welds 80
3 Tension 90
4 Compression 100
5 Shear 55
2010 E.C Page 77

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EIT-M

SCHOOL OF MECHANICAL AND INDUSTRIAL

Design and Modeling of Crop

Advisor: Zebenay T.(Msc)

2010 E.C Page 1

1.1. Problem Statement

Figure1.1. Ethiopian farmers when they cutting-harvesting of crops

2010 E.C Page 2

1.3. Significance of Study

2010 E.C Page 3

Figure2.1. Reaping Hook

Figure2.2. The Scythe

2010 E.C Page 4

Figure2.3. The Cradle

Figure2.4. The World's First Reaper

2010 E.C Page 5

Figure2.5. McCormick’s Patent Reaping Machine

Figure2.6. McCormick's Patent Reaping and Mowing Machine

2010 E.C Page 6

Figure2.7. McCormick Combination Reaper and Mower

Figure2.8. The Marsh Type Harvester

2010 E.C Page 7

Figure2.9. McCormick Harvester and Binder

Figure2.10. McCormick Harvester and Binder

2010 E.C Page 8

Figure2.11. McCormick Harvester and Binder

Figure2.12. McCormick-Deering Tractor Binder

Figure2.13. McCormick-Deering Harvester-Thresher

2010 E.C Page 9

Figure2.14. The Windrow-Harvester

2.1.5. Riding Type Self- Propelled Reaper

Figure2.15. Riding type self- propelled reaper

Figure2.16. Self- propelled vertical conveyor reaper

2.1.7. Self-Propelled Reaper Binder

Figure2.17. Self-propelled reaper binder

2010 E.C Page 11

2010 E.C Page 12

Data collection method

Identify customer need

Generate product concept

Select product concept

2010 E.C Page 13

Table4.1. Preparing relative importance of needs

Product design needs Level of importance

2010 E.C Page 14

2010 E.C Page 15

Figure4.2. Manually operated crop-cutting machine powered with electric motor

2010 E.C Page 16

Table4.3. Material selection for Model B

Number Components Material

2010 E.C Page 17

Table4.4. Material selection for Model C

Number Components Material

2010 E.C Page 18

2)shafts that connected with slider

2010 E.C Page 19

Table4.5. Material selection for Model D

Number Components Material

2010 E.C Page 20