DESIGN AND FABRICATION

OF COST EFFECTIVE AND

MULTIPLE – CASHEW NUT
CUTTING MACHINE

A PROJECT REPORT
Submitted by

NAMBU SAKTHI N (1912061)

ARANGANATHAN (2012006)
HARIHARAN P (2012029)
LAKSHMANAN G (2012048)

In the partial fulfillment for the award of degree

of

BACHELOR OF ENGINEERING
In
MECHANICAL ENGINEERING

ALAGAPPA CHETTIAR GOVERNMENT COLLEGE OF

ENGINEERING AND TECHNOLOGY, KARAIKUDI-630003

(An Autonomous Institution; Affiliated to Anna University, Chennai - 600 025)

ANNA UNIVERSITY: CHENNAI 600 025

APRIL 2024

i
 ALAGAPPA CHETTIAR GOVERNMENT COLLEGE OF
ENGINEERING AND TECHNOLOGY, KARAIKUDI-630003
(An Autonomous Institution; Affiliated to Anna University, Chennai -600025)

BONAFIDE CERTIFICATE

Certified that this project report “DESIGN AND FABRICATION OF COST

EFFECTIVE AND MULTIPLE-CASHEW NUT CUTTING MACHINE” is the

bonafide work of NAMBU SAKTHI N (1912061), “ARANGANATHAN (2012006),

HARIHARAN P (2012029) and LAKSHMANAN G (2012048)” of VIII semester

who carried out the project work under my supervision.

SIGNATURE SIGNATURE

Dr.K.RAMANATHAN, M.E, Ph.D. Mr.C.SATHISHKUMAR, M.E,

HEAD OF THE DEPARTMENT SUPERVISOR,
Department of Mechanical Engineering ASSISTANT PROFESSOR
Alagappa Chettiar Government College Department of Mechanical Engineering
of Engineering and Technology, Alagappa Chettiar Government College
Karaikudi-630003. of Engineering and Technology,
Karaikudi-630003.

Submitted for the"19MEZ81-Project Work” viva-voce examination held on ____________.

INTERNAL EXAMINER EXTERNAL EXAMINER

ii
 ACKNOWLEDGEMENT

First and foremost is our duty to thank the Almighty for being with us all the
time and bring out this project with flying colors.

I are greatly obliged to Dr.BASKARAN, M.E, Ph.D., Principal, Alagappa

Chettiar Government College of Engineering And Technology, Karaikudi, for giving
us this wonderful opportunity to do the project within our campus.

I would like to express our hearty thanks to Dr.K.RAMANATHAN,M.E,

Ph.D., Head of the Department, Mechanical Engineering for granting us permission
to carry out this project.

I would like to thank our Guide Mr.C.SATHISHKUMAR,M.E, Assistant

Professor, Department of Mechanical Engineering for granting us permission to do
this project and guided us all through our works and was encouraging all our efforts
to make this Project a success.

I would like to thank our faculty advisor Dr.R.SARALA, M.E, Ph.D.,

Associate Professor, Department of Mechanical Engineering who gave us enormous
support and motivated us to do this project with great success.

Also I extend my thanks to my family and friends who helped and supported
us during all the times day and night.

iii
 ABSTRACT

The project aimed to design and fabricate a cost-effective multi-cashew

nut cutting machine for very low, small and medium scale capital companies

in the cashew processing industry. This is a manual operation machine rather

than an expensive fully automatic cashew cutting machine where the

companies with low capital cannot afford so through extensive research on

field of the low capital companies area, a design with multiple cutting blades,

adjustable parameters, and a compact footprint was developed to reduce time

and increase productivity of the cashew shelling process. The fabrication

process focused on using locally sourced materials and stringent quality

control. The machine's features include user-friendly controls, and low

maintenance requirements. The project successfully addressed the specific

needs of very small-scale and low initial capital cashew shelling units, aiming

to contribute to the growth and sustainability of very small businesses in the

industry.

iv
CHAPTER TABLE OF CONTENTS PAGE
NO NO
TITLE OF CHAPTERS
ABSTRACT iv
LIST OF TABLES vi
LIST OF FIGURES vii
I INTRODUCTION 1
1.1 HISTORY OF CASHEWS 2
1.2 CASHEW PROCESSING STAGES 4
1.3 MARKET STRUCTURE 6
II LITERATURE REVIEW 7
2.1 EXISTING CASHEW CUTTING MACHINES 10
2.2 IDENTIFICATION OF PROBLEM 12
III METHADOLOGY 13
3.1 PARTS OF THE MACHINE 15
3.2 MACHINERIES AND WORKSHOP USED 16
IV CONCEPTUAL MODELLEING, DESIGN 18
CALCULATION AND FABRICATION PROCESS
4.1. 3D MODELLING IN CATIA V5 18
4.2 MATERIAL AND SPECIFICATION 21
4.3 DESIGN OF SHAFT AND BALL BEARING 26
4.4 FABRICATION 31
4.5 LIMITATIONS AND ADVANTAGES 35
4.6 GENERAL APPLICATION 37
V RESULT AND CONCLUSION 38
REFERENCES 39

v
 LIST OF TABLES

TABLE TITLE PAGE

NO NO

4.1 SPECIFICATION OF MILD 24

STEEL

vi
 LIST OF FIGURES
FIG TITLE PAGE
NO NO
1.1 FLOW CHART OF CASHEW 5
PROCESSING
2.1 SINGLE CUTTING MANUAL 10
CASHEW CUTTING MACHINE
2.2 SEMI-AUTOMATIC CASHEW 10
CUTTING MACHINE
2.3 FULLY AUTOMATIC CASHEW 11
CUTTING MACHIN
4.1 3D MODEL OF PRESSING 19
BLADE
4.2 3D MODEL OF CASHEW 19
CUTTING BLADE KIT
4.3 3D MODEL OF CASHEW BED 20
4.4 FINAL ASSEMBLY OF MACHINE 20
4.5 MILD STEEL ROD 21
4.6 BALL BEARING 22
4.7 CASHEW CUTTING BLADE KIT 22
4.8 MAX COMBINED STRESS 27
4.9 TOTAL BENDING MOMENT 27

4.10 MILD STEEL SHAFT CUTTING 32

4.11 MAKING PRESSING BLADE 32

vii
 LIST OF FIGURES

FIG TITLE PAGE

NO NO

4.12 METAL PLATE CUTTING BY 33

BANDSAW MACHINE
4.13 DRILLING HOLE IN THE 33
SQUARE TUBE
4.14 FABRICATED MACHINE 34

viii
 CHAPTER I
INTRODUCTION

In today’s competitive market landscape, very small and medium-sized

enterprises (SMEs) face numerous challenges, particularly in accessing
affordable and efficient machinery to streamline their operations. In the cashew
processing industry, where profit margins are often tight, the need for cost-
effective solutions is paramount. Our project, focused on the design and
fabrication of a cost-effective and multi-functional cashew cutting machine,
specifically caters to the requirements of low capital companies aiming to
enhance productivity while minimizing investment costs.

The cashew processing sector, renowned for its labor-intensive nature,

presents a significant opportunity for innovation aimed at reducing manual
intervention, increasing efficiency, and optimizing resource utilization. However,
the prohibitive costs associated with acquiring advanced machinery often deter
small-scale enterprises from adopting modern processing techniques.
Recognizing this gap, our project endeavors to develop a solution tailored to the
needs and constraints of low capital companies.

Our primary objective is to design and fabricate a cashew cutting machine

that not only meets the operational requirements of small-scale enterprises but
also remains affordable and economically viable. By leveraging innovative
design principles, cost-effective materials, and efficient manufacturing
processes, we aim to create a machine that offers a competitive edge to low
capital companies in the cashew processing industry.

Key considerations driving our design include affordability, simplicity,

ease of operation, and versatility. We aim to develop a machine that requires
minimal initial investment, operates efficiently with low maintenance costs.
1
1.1 HISTORY OF CASHEWS

The word cashew comes from the Tupi-Indian word Acaju, which means
“nut”. Instead of growing like conventional nuts, they grow out of the base of
cashew apples like little tails. However, for this reason, they are the only ‘nut’
that sells solely without a shell. The outer shell causes skin irritation.

The seed has a double shell containing an allergenic phenolic resin

containing an anacardic acid. This composition is a potent skin irritant.
Chemically, this resin is related to the more well-known allergenic oil urushiol,
a toxin in poison ivy. Some people are allergic to cashew nuts. What is much
more common is the allergy to the outer coating on the fruit’s skin.

The cashew was first discovered by Europeans in Brazil around 1558.

Because of the irritating shells, they were thought to be inedible at first. Over
time, there was a realization that it was the fruit skin, not the irritating seeds. It
was the local native tribe, the Tupi-Indians that showed the Europeans otherwise.
Consequently, the Portuguese were shown to roast the cashews to get the irritant
off.

Europeans found the cashew seed to be quite tasty. However, they also
used the cashew apple pulp to make wine. The natives had learned to eat cashews
from the local capuchin monkeys.

The Modern History of the cashew: As a consequence of finding out how

to reach the cashew seed, the Portuguese brought cashews to Goa in about 1560.
Ultimately, the nut thrived in the new climate and then traveled to India soon
22after. The Indian people discovered healing properties in the nut, and cashews
Became very popular. In the second half of the 16th century, cashews spread to
2
Southeast Asia and Africa. Eventually, many countries and cultures currently
depend on cashew seeds as a food staple and for commerce.

The modern history of cashew shows that they reached the United States
around 1905. Afterward, cashews became popular in the mid-1920s when the
General Food Corporation started to ship them regularly to the United States and
Europe. Ultimately, the cashew became popular. By 1941, looking at the number
of imports from India annually was 20,000 tons of cashews.

The cashew tree is large and evergreen, growing to 14 meters (46 feet)
tall, with a short, often irregularly shaped trunk. The leaves are spirally arranged,
leathery textured, elliptic to obviate, 4–22 centimeters (1+1⁄2–8+3⁄4 inches) long
and 2–15 cm (3⁄4–6 in) broad, with smooth margins. The flowers are produced
in a panicle or corymb up to 26 cm (10 in) long; each flower is small, pale green
at first, then turning reddish, with five slender, acute petals 7–15 millimeters
(1⁄4–5⁄8 in) long. The largest cashew tree in the world covers an area around
7,500 m2 (81,000 sq.ft) and is located in Natal, Brazil.

The fruit of the cashew tree is an accessory fruit (sometimes called a

pseudo carp or false fruit). What appears to be the fruit is an oval or pear-shaped
structure, a hypocarpium, which develops from the pedicel and the receptacle of
the cashew flower. Called the cashew apple, better known in Central America as
Maranon, it ripens into a yellow or red structure about 5–11 cm (2–4+1⁄4 in)
long.

3
1.2 THE CASHEW PROCESSING STAGES

The raw cashew nut processing process starts with properly drying and
storing the raw cashew nuts for processing all year round. The next steps involve
various activities to remove the cashew kernel from its shell. The final edible
consumer product is the cashew kernel. This complex process results in high
value addition to the raw cashew nut.
The objectives of raw cashew nut processing are:

• Removing the highest possible weight of kernels from the raw cashew nut
• Avoiding breakage of the kernels
• Ensuring that the distinctive light ivory cashew color is maintained
• Maintaining the natural taste of the kernels. Note that naturally tasting cashew
kernels are free from chlorophenol off flavors.
• Ensuring kernels uphold internati4onal food safety standards for consumption

The achievement of these objectives results in obtaining high quality

cashew kernels at competitive prices. Unlike almonds or hazel nuts, where the
nut is enclosed in an otherwise hollow shell, the cashew kernel is cushioned in a
hard shell by a honeycomb layer called the testa. Thus, processing the raw
cashew nut involves more complex steps to obtain the half-moon shaped, light
ivory and naturally tasting kernel. Raw Cashew Nut processing involves three
(3) key stages:

a) Heat treatment: The application of direct heat, hot oil or steam, prepares the
raw cashew nuts for shelling and facilitates removal of the shell

b) Shelling and peeling: The hard shell is either cracked or cut to expose the

4
 kernel with test for separation from the shell. The test of the cashew kernel
has to be removed after shelling. The white kernels are obtained after
removing the shell and the test. The shells contain the corrosive Cashew Nut
Shell Liquid (CNSL) which can burn or blister the hands of workers. It can
also cause damage to cashew processing machinery.

c) Grading: The final stage of the primary processing process is the

classification of kernels and packaging for distribution and sale.

These three basic (3) stages of raw cashew nut processing involve
different methods of heating, shelling and peeling. The application of any
method depends on available technologies and resources such as access to
electricity, water and labor as well as the knowledge of local customs.

Fig 1.1 flow chart of cashew processing

5
 1.3 MARKET STRUCTURE

It is important for processors or investors who are intent on building new

factories or upgrading or replacing existing machines, to understand how the
cashew processing equipment market works. The cashew processing equipment
market is changing and developing. As mentioned above, new entrants, new
technology and new investors in cashew processing have changed the processing
equipment market and the machines produced.

Manual processing still plays a part, but mainly in small units and in pre-
process units where, for example, shelling is done before the nuts are sent for
peeling and grading at the main plant. However, the vast majority of cashew
processing plants throughout the world are semi mechanized, with machines for
processing linked together in a production line, and product moved from one
section to the next manually or by conveyor. There are a handful of fully-
mechanized or continuous process plants where conveying of the product as well
as the process itself is conducted by machines supervised by a few workers.
These plants are usually large scale.

A rough guide for full mechanization is that capacity of RCN to be

processed should be a minimum of 10,000 tonnes per annum. For semi-
mechanized or mixed manual/mechanized plants, there are a range of machines
which can be efficiently utilized for capacity as low as 1,200 tonnes p.a.,
although that level is not ideal. There are also small scale machines (e.g.
standalone low capacity shelling machines or the “mini fabrica” systems found
in Brazil) which can be used in factories with capacities as low as 500 tonnes
per annum.

6
 CHAPTER II
LITERATURE REVIEW

In recent years, the cashew industry has seen significant growth,

particularly among very low capital and small-scale companies. To meet the
demand for processed cashew nuts, there is a need for cost-effective and multiple
cashew cutting machines that can improve efficiency and productivity. This
literature review aims to explore the existing technologies and advancements in
cashew cutting machines suitable for small-scale companies with low capital
investment.

 S. J. Ojolo B. Ogunsina Agricultural and Food Sciences 2007

The traditional method of cracking roasted cashew nuts manually, using

harmer or knife cutter is labor-intensive, slow and tedious; besides, most
mechanical crackers do not give satisfactory results in terms of whole kernels
percentage. A prototype machine was developed to crack roasted cashew nuts.
The box-like machine has a hinged and spring-loaded mild steel cracking lid
with grooves to hold a cast aluminum feeding tray which was machined to hold
25 nuts at a time. Nuts get cracked by the impact of the lid against the feeding
tray. The lid provides for a minimum clearance from the feeding tray on which
nuts are preloaded; this prevents the applied force from being in excess of the
required cracking force. The machine was tested with various cashew nut sizes,
and placement orientations.

The percentage of whole kernels produced was 66.66 %. The capacity of

the machine was estimated to be about 18.3 kg/hr. A device of this nature can be
manufactured for small entrepreneurs and village-level applications in the
developing countries where bulk of the world cashew is produced.
7
 A. Bamgboye Agricultural and Food Sciences 2008

Thorough knowledge of the physical properties of cashew nuts in its

present form is necessary in the design of its shelling machine. A study was
carried out to determine the effects of pre-treatment by hot oil roasting and steam
boiling on the physical properties of cashew nut.

Samples of cashew nuts obtained from five plantations in Iseyin area of

Oyo State and Iwo in Osun State in the South-Western Nigeria were used in this
work. About 3kg of nuts were picked from 20 randomly selected trees in each
of the plantations. The cashew nuts were subjected to pre-treatment by steam
boiling and hot oil roasting.

The physical properties of raw and pre-treated cashew nuts were

determined using standard methods. The results showed that nuts from South-
Western Nigeria, which were used for the experiment, could be classified as
medium large and extra-large ie 22-35 mm. The pre-shelling treatment showed
significant difference (P<0.05) in the means of length and width of cashew nut,
and no significant difference for thickness, aspect ratio and sphericity index.

The treatment showed significant difference (P<0.05) in true and bulk

densities but showed no difference in the porosities of the nuts. The moisture
content of raw kernel was significantly different (P<0.05) from that of roasted
and steam-boiled kernels. The physical properties of cashew nuts were found to
be affected by pre-treatment by hot oil roasting and steam boiling.

8
 Jain, R.K. and Kumar, S. (1997), Journal of Food Engineering

The shelling efficiency was evaluated on the basis of the number of completely
shelled nuts per batch of 50 nuts. Results indicated that out of every 50 nuts an
average of 48 nuts were completely shelled, thus giving a shelling efficiency of
95 per cent; this is higher than 70 per cent obtained by Jain and Kumar (1997)
for motorized sheller.

The whole kernel recovery, evaluated on the basis of the number of

kernels recovered unbroken out of every batch of 50 nuts shelled, indicated that
a mean number of 35 nuts out of every 50 nuts were recovered whole. The whole
kernel recovery was 70 per cent. The shelling efficiency of the cashew nut sheller
has a higher shelling efficiency than that obtained from the manual sheller by
Ajav (1996) which was 67-75 per cent, and a manual cashew nut cracking device
by Ojolo and Ogunsina (2007).

The whole kernel recovery was higher than 50 per cent obtained by Jain
and Kumar (1997) for a semi-automated sheller and 67 per cent that was
obtained by Ojolo and Ogunsina (2007) for a manual cashew nut cracking
device. The throughput (15.475 kg/h) is much higher than 21 kg of nuts/day (that
is, 0.875 kg/h) achievable by manual shelling of nuts using a mallet or batten
(Azam-Ali and Judge, 2004). Optimum processing and pre-shelling treatments
also play a vital role in the shelling characteristics of cashew nut
(Thivavarnvongs et al., 1995).

9
2.1 EXISTING CASHEW CUTTING MACHINES
Cashew cutting machines come in a variety of variations and models, each
with its own benefits and drawbacks for different users. There is, of course, the
basic walking cane as shown in Fig. 2.1, it is a manual cashew cutting machine
with one cutting at a time and a pressing blade handle on the top that is usually
made up of mild steel. This is the simplest design, where most of the very small-
scale companies look like good investments, but it is really overrated for the
price in the market, and its productivity is comparatively low.

Fig.2.1 single cutting manual cashew cutting machine

Another machine is an addition with a motor, a pneumatic system, or any

other actuator system that is connected to a pressing blade with an allowable
thickness blade, which makes the machine semiautomatic, but this reduces the
physical effort for the worker but, on the other hand, increases the maintenance
cost and electricity charge, which will be more suitable for medium-scale
companies.

Fig.2.2 Semi-automatic cashew cutting machine

10
 The next type of cashew cutting machine is the fully automatic cashew
cutting machine, which does not require any human interface while shelling
cashew nuts after roasting (Fig. 1.3). The major difference between the semi-
automatic and fully automatic is that the semi-automatic self-aligns the cashew
nut for shelling and gets the kernel out of the nut. This fully automatic cashew
cutting machine is not affordable for all but only for those who have large initial
capital investments, which will pose a huge challenge for small businesses, and
who have very low capital investment.

Fig.2.3 Fully automatic cashew cutting machine

11
2.2 IDENTIFICATION OF PROBLEM

Overall productivity: The existing cashew cutting machine has some

flaws, like the fact that it can break the nuts only one at a time. It is also a
complex machine with high maintenance and an overrated price in the market.

High cost for automated and advanced systems: very small scale
companies won’t be able to afford high cost automatic cashew cutting machine
thus pose a huge obstacle for them enter the cashew processing sector and
compete other industries.

Environmental Impact: Increased mechanization in cashew processing

may lead to higher energy consumption and environmental footprint, especially
if the electricity used is sourced from non-renewable sources

Rapid challenges: Challenges like power shutdown or any problem in

power supply may lead to halt the automatic production line

Dependence on Electricity: Semi-automatic and automatic machines

rely on consistent electricity supply, making them vulnerable to disruptions
caused by power outages or fluctuations, especially in rural areas or regions with
unreliable infrastructure.

Job Displacement: Automation in cashew processing can lead to job

displacement among manual laborers, impacting livelihoods in communities
where cashew processing is a significant source of employment.

12
 CHAPTER III
METHADOLOGY

Design and Planning: Develop a detailed design for the multiple cashew
cutting machine, considering factors such as dimensions, materials, ergonomics,
and functionality. Create 2D and 3D models using computer-aided design
(CAD) software to visualize the final product.

Material Selection: Identify the appropriate materials for different

components of the multiple cashew cutting machine. Consider factors such as
strength, weight, durability, and cost. Common materials used in the project
include mild steel for almost all the components.

Procurement: Procure the required materials and components from

reliable suppliers based on the specifications and quantities needed for the
project.

Preparation and Cutting: Prepare the materials for fabrication by cutting

them into the required dimensions. Use appropriate cutting tools such as band
saw machine, saws, shears, or CNC machines to achieve precise cuts.

Machining and Shaping: Employ machining techniques like milling,

drilling, or turning to shape and refine the components. This step involves
creating holes i.e. drilling, chamfers, or other required features on the metal.

Welding and Joining: If necessary, use welding techniques to join metal

components together. This step involves techniques like TIG (Tungsten Inert
Gas) welding or MIG (Metal Inert Gas) welding to create strong and durable.

13
 Assembly: Assemble the various components of the multiple cashew
cutting machine according to the design specifications. This includes attaching
the pressing blade attached to the shaft and bearings to the frame and connecting
the standard kit for shelling cashew and getting the whole kernel.

Finishing: Apply finishing treatments such as sanding, polishing, or

coating to enhance the aesthetics and durability of the product. This step may
involve processes like powder coating, anodizing, or painting.

14
3.1 PARTS OF MACHINE

Shaft: Which is attached to the pressing blade which presses the cashew
nut into the cashew cutting blade kit where it initially pierce the nut and then
separate the shell of the nut more widely.

Ball bearing: This is a fixed mounted ball bearing to hold the shaft for
providing required circular motion of the pressing blade

Pressing plate 4mm thick plate This plate is for pressing the cashew
inside the cashew cutting kit for getting whole cashew kernel rather than half
of kernel which has low

Cashew cutting kit This kit is readily available in the market for
reasonable price where we can use it for obtaining the whole kernel when the
roasted cashew nut is put inside it and pressed with the pressing blade which
is attached to the square tube which is further attached to the shaft and bearing
there are three main parts in the kit-

Circular cutting blade this part which cut the cashew nut initially in
both the side when pressed by the pressing blade.

V separator blade after the circular blade cuts the kernel, the v separator
expands the nut way more and produces the whole kernel as output.

Frame: The frame which is used to hold all the above parts and to get
a firm support to the ground.

15
3.2 MACHINERIES AND WORKSHOPS USED

TIG Welding: Tungsten Inert Gas (TIG) welding is a precise arc welding
process utilizing a non-consumable tungsten electrode to create welds. The
electrode heats the metal, while an inert gas, typically argon, shields the weld
area from atmospheric contamination. TIG welding excels in producing high-
quality, clean welds, particularly in thin materials and intricate weld joints. It
offers precise control over the welding parameters, making it suitable for a wide
range of materials including stainless steel, aluminum, and exotic metals. The
frame links and cashew bed are to be joining by welding for strong attachment.

Gas Cutting: Gas cutting is a thermal cutting process where a high-

temperature flame, typically fueled by acetylene or propane, is directed onto the
work piece. The intense heat melts the material, while a stream of oxygen blows
away the molten metal, creating a clean cut. Gas cutting is versatile and
commonly used for cutting thick steel plates, pipes, and structural components
in various industries like construction, manufacturing, and shipbuilding. This
process is used to cut the pressing blade with the required shape and dimension.

Lathe Operation: A lathe is a machine tool used for shaping cylindrical

work pieces by rotating them against cutting tools. Lathe operations involve
turning, facing, drilling, and threading operations to create precise symmetrical
components. The work piece is secured on the spindle and rotated at varying
speeds while the cutting tool is brought into contact with the material to remove
excess material and shape it to the desired dimensions. These machining was
used to turning the shaft for the required diameter which will fit into the ball
bearing.

16
 Drilling Machine: A drilling machine is a versatile tool used for creating
holes in various materials such as metal, wood, and plastic. It operates by
rotating a cutting tool, known as a drill bit, which applies axial force to penetrate
the work piece. Drilling machines come in various types including bench drills,
pillar drills, and radial drills, each suited for different applications ranging from
light-duty tasks like home repairs to heavy-duty industrial drilling operations in
manufacturing and construction. These machining was done to drill holes into
the rectangular plate for holding the cashew cutting kit and to hold the ball
bearings which is attached to the frame various drill bit like 16mm,8mm and
6mm bits are used in drilling the plate to hold cashew cutting kit.

Grinding Machine: Grinding machines are used to remove excess

material or achieve high precision surface finishes through abrasive cutting.
These machines utilize grinding wheels with abrasive particles to remove
material from a work piece’s surface, producing smooth and precise finishes.
Common types of grinding machines include surface grinders, cylindrical
grinders, and tool and cutter grinders, each designed for specific applications
such as sharpening tools, grinding cylindrical surfaces, or creating flat surfaces
with tight tolerances. Grinding machines find extensive use in manufacturing
processes across industries including automotive, aerospace, and tooling. This
machine was utilized for grind down the small unwanted particles in the
components and to get the good surface quality finish in the product.

17
 CHAPTER IV
CONCEPTUAL MODELLING, DESIGN CALCULATION
AND FABRICATION

4.1 3D MODELLING IN CATIA V5

CATIA V5, developed by Dassault Systèmes, is a culmination of decades

of innovation and evolution in computer-aided design (CAD) software. Its
history traces back to the early 1970s when Dassault began developing
CAD/CAM software for their aerospace projects. In 1977, Dassault launched
CATIA (Computer-Aided Three-dimensional Interactive Application), which
revolutionized the design and manufacturing processes in aerospace and other
industries. The early versions of CATIA were primarily used for 2D drafting and
basic 3D modeling.

However, it wasn't until the 1990s that CATIA truly began to take shape
as a comprehensive CAD/CAM/CAE solution with the release of CATIA V4.
This version introduced significant improvements in 3D modeling, assembly
design, and drafting capabilities. It became widely adopted in industries such as
automotive, aerospace, and consumer goods for its advanced features and ability
to handle complex design requirements.

Today, CATIA V5 remains a cornerstone of product development for

companies worldwide, enabling innovation and driving efficiency in the design
and manufacturing processes. Its rich history reflects the ongoing commitment
of Dassault Systèmes to push the boundaries of CAD technology and empower
designers to bring their ideas to life in the most efficient and effective way
possible.

18
 Fig 4.1 3D model of pressing blade

This part consists of a shaft (green colour), a square tube bar (yellow
colour), and a pressing blade (purple colour). He Here, the shaft will be fixed in
the ball bearing, and it will possess reciprocating rotation.

Fig 4.2 3D of cashew cutting kit

This part consists of a circular blade (green) to cut the cashew

symmetrically and a V separator blade (brown) to separate the cashew nut shell
even greater, and it is readily available in the market extensively and designed
specifically to produce shelled cashew to whole kernels rather than half or
broken. It is tighten with nuts and bolts.

19
 . Fig 4.3 3D model of cashew bed

This part consists of support links for fixing the shaft, a ball bearing, a
cashew cutting kit, and a compression spring (blue), which acts as a horizontal
push for the one-side cashew cutting kit in order to cut the cashew when placed
inside the cashew cutting kit.

ASSEMBELED

Fig 4.4 3D model of assembled multiple cashew cutting machine

This consists of fully assembled parts and represents the final, promising
design after numerous iterations of creating the conceptual design. The
assemblage can be done by welding, drilling, and tightening with holes and nuts.

20
 4.2 MATERIALS AND SPECIFICATION

SHAFT IN THE PRESSING BLADE

This shaft plays a crucial role in the cashew cutting machine, where it acts
as a revolute joint that is attached to a bearing, and the shaft is connected to a
square tube, which is then welded to the pressing rod for exerting force or cashew
nuts in order to obtain whole cashew.

 Assuming a adult can exert a force of 20N to 50N on the end of the blade

 The length from shaft to the blade end 60cm or 0.6m or 600mm

 Out of the many materials two are commonly used for the center rod mainly Mild
steel and carbon steel.

 Carbon steel is eminently satisfactory for normal support function for walking,
but its cost is higher compared to Mild steel.

 Mild steel is suitable since it is obtained in a wide variety of diameters, has a
light weight, and has more strength and easily affordable.

Fig.4.5. Mild steel shaft

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FIXED MOUNTED BALL BEARING

This ball bearing which is made up of zinc alloy and holds the shaft of the
pressing blade which has a shape of trapezium with 4mm thickness. Fixed
mounted ball bearings play a crucial role when attached to a rotating shaft,
providing stable support and facilitating smooth rotational motion. By securely
fastening to the shaft, these bearings ensure that the shaft maintains its position
and alignment during operation, thus preventing any undesirable wobbling or
misalignment. This secure attachment minimizes vibration, reduces friction, and
enhances the overall efficiency of the rotating assembly.

Fig.4.6. Ball bearing

CASHEW CUTTING BLADE KIT

This kit consists of a pair of circular blade, a pair of separator, a

compression spring and a pair of holder and nut and bolt for holding the setup
which is all made up of mild steel and the nuts and bolts are galvanized iron and
mild steel.

Fig.4.7. Cashew cutting kit

22
SPECIFICATION OF MILD STEEL

Mild steel is an alloy composed mostly of iron and carbon. It also contains
small amounts of manganese, phosphorus, sulfur, and silicon. This combination
makes it highly malleable and ductile while still maintaining its strength and
hardness. Its low cost makes it ideal for many projects that require structural
integrity without breaking the bank.

Composition of Mild Steel

Mild steel has long been a staple material in the manufacturing industry due
to its versatility and strength. Its composition is primarily made up of iron and
carbon, with a maximum limit of 0.25% carbon content. This low carbon content
allows for superior weldability and formability compared to other high carbon
steels. However, the drawback to its low carbon content is that mild steel is not
as hard as other steels and can be susceptible to corrosion.

Properties of Mild Steel

Mild Steel is known for its strength and durability. It also has good
weldability and machinability, making it easy to fabricate into different shapes
and sizes. This makes it ideal for use in many industries, such as aerospace,
construction, and automotive manufacturing. The strength of mild Steel also
means that it can be used to create structures that can withstand heavy loads or
harsh weather conditions.

23
Melting point of mild steel

Mild steel is a popular choice for buildings and structural elements, due
largely to its malleability and durability. But what really sets it apart from other
materials is its high melting point of 1350oC-1530oC (2462oF-2786oF). This
makes it the ideal material for applications that require strength in areas exposed
to high temperatures. It also excels as a construction material in areas prone to
fires since it will take longer to melt than other metals and offers better protection
against flames.

Versatility of Mild Steel

Mild Steel also stands out from other materials due to its versatility; given
its malleability, it can be bent into almost any shape desired without
compromising its structural integrity or durability. This makes it perfect for
creating custom parts for various purposes, such as furniture frames, automotive
parts, pipes, etc., where the desired shape cannot be achieved through traditional
means such as cutting or welding. For this reason, mild Steel is highly sought
after by both industrial companies and everyday consumers.

SPECIFICATIONS VALUES

Yield Strength 250 MPa

Tensile strength 1700 MPa

Density 7850kg/m3

Table.4.1. Mild Steel specifications.

24
SPECIFICATION OF ZINC ALLOY

After iron, aluminium and copper, zinc is the fourth most widely used
metal in the world. About 13.2 million metric tons of refined zinc metal was
produced globally in 2018, and this level of production has remained largely the
same over the last decade. China is the world's largest producer of zinc,
contributing almost 40% of the global output, while Australia has the largest zinc
reserves in the world.

Zinc is the 16th most abundant metal and 23rd most abundant element in
earth's crust, respectively. It is more abundant than copper, although global
copper production is considerably more than that of zinc. Global zinc production
is primarily from its ore, zinc sulphide, commonly known as sphalerite.

Almost half of all the zinc produced is used for galvanisation; the process
of coating iron or steel with a thin layer of zinc to protect it from corrosion. This
process can drastically increase the recyclability of steel and iron. Aside from
being used for galvanisation, zinc is heavily used for making alloys, the most
common being brass. Brass is an alloy of copper and zinc with smaller amounts
of lead and tin.

Aluminium also improves some mechanical properties such as elongation.

Copper is another common constituent in zinc alloys. Copper-zinc alloys, also
known as brass, have enhanced properties such as tensile strength, hardness,
wear resistance, and creep.

Magnesium, in relatively small quantities, is an important zinc alloying

metal as it improves the grain structure and prevents inter-granular corrosion
typically caused by impurities.

25
4.3 DESIGN OF SHAFT AND BALL BEARING

Design of shaft
 Assuming an adult can exert a force of 20N to 50N on the end of the
blade[2].

 The length from shaft to the blade end 60cm or 0.6m or 600mm.

To find the diameter of the shaft

2 2
Equivalent Twisting moment, T equivalent = √ (M + T ) (moment × torque)

 Therefore Torque at shaft

T=F×D
T= 50×0.6 = 30Nm or 30000Nmm
T equivalent = torque
3
T equivalent = π/16 × τ × d ,
Where d is the diameter of the shaft and τ is the shear force.
 The selected material is Mild steel whose yield strength
2
σy = 260 N/mm

Assuming factor of safety n = 2, the working stress σ = σy ÷ n

2
∴ σ = 260 ÷ 2 = 130N/mm
 Also Shear stress τ=σ÷2
2
∴ τ = 130 ÷ 2 = 65N/mm

3
 Therefore d = √((30000×16) ÷(3.14×65))

= 13.2mm

26
 STRUCTURAL ANALYSIS OF THE SHAFT

Structural analysis is the prediction of the response of structures to

specified arbitrary external loads. During the preliminary structural design stage,
a structure’s potential external load is estimated, and the size of the structure’s
interconnected members are determined based on the estimated loads.

Fig4.8 Maximum Combined Stress

The stress generated max and min are 0.042433Mpa and 1.75e-16Mpa.

Fig4.9 Total bending moment

The maximum and minimum bending moment generated on the shaft is 112.24Nmm
and4.6491e-13.

27
 Design of ball bearing by iteration approach

1. Selection of bearing

2. Finding equivalent load (Axial load Fa and radial load Fr )

3. Finding Static (C0) and Dynamic capacity (C)

4. Checking safe or not safe

Selection of bearing

From PSG data book Page No: 4.14

 we select a Deep grove ball bearing of 15BC03, Bearing of basic design No
(SFK) 02

 Inner diameter d of 15mm,

 outer diameter of 21mm

 Static capacity C0 = 520Kgf or 5099.458N

 Dynamic capacity Cd = 880Kgf or 8629.8519N

Finding equivalent load (Axial load and radial load)

From PSG data book Page No: 4.2
 Equivalent load P = (X Fa + Y Fr )S ,where X - Radial factor,
Y - Thrust factor
Fa -Axial load, Fr -Radial load
S - Service factor
28
 Since the Bearing is going to subjected to reciprocating movement
∴ S = 1.5 (PSG DB 4.2)

 Assumed Radial load as self-weight of the cutting part with blade acting on it

 The Axial load Fa will be very negligible which is produced by shaft therefore
it is neglected.

∴ Fr = (mass of square tube + mass of pressing blade) × 9.81

Mass of square tube of dimension

Length (60cm) × Side (2.5cm) ×Thickness (0.4cm)

∴ Mass of square tube = 1.58kg

Mass of pressing blade (MS steel) which resembles as a plate with thickness 4mm
Density of MS Steel = 7850 kg/m3

Area of trapezium = 0.052m2

Volume of trapezium = Area of trapezium × thickness
= 0.052 ×0.004
=0.000208 m3

∴ Mass of pressing blade = 7850×0.000208 =1.6kg

29
 ∴ Fr = (1.58+1.6) × 9.81 = LESS THAN 58N (31.1958N)

∴ P = (X Fa + Y Fr) S Where Y = 2 (PSG DB Page No.4.4)

P = (0+ (2 ×58)) 1.5 = 174 N

Calculate dynamic capacity

From Page No. 4.6

Assuming the bearing is going to use for 9hr/day for 5 years

∴Life hours Lh = 9 × 365 ×5 = 16425hrs ≈ 20000

From the RPM v/s LIFE IN HOURS graph we assumed 16 rpm with 20000 hrs

∴ We get C/P = 6.2

∴ C = 174 × 6.2 =1078.8N

 Checking safe or unsafe ⟹ C < Cd (1078.8 < 8629.8519)

Therefore Design is safe

30
4.4 FABRICATION

Stage 1: Develop a simple square frame for attaching the bearing and the cashew
cutting kit.

Stage 2: Cutting the Mild Steel rod for support to the pressing blade at one end,
which is attached with the fixed mounted ball bearing.

Stage 3: welding the pressing blade to the square tube.

Stage 4: creating holes in the square tube same as the shaft diameter.

Stage 5: Attach the fixed mounted ball bearing on the frame along with the
pressing blade to it.

Stage 6: Assemble the cashew cutting kit orderly and facing one to one each
other.

Stage 7: align the kit in the correct order and tighten the nut and bolts at
applicable areas.

31
Fig 4.10 MS Steel shaft cutting

Fig.4.11. Making of pressing blade

32
Fig.4.12. metal plate cutting using Band saw machine at ACGCET

Fig 4.13 drilling hole in the square tube of the pressing tube

33
Fig4.14 Fabricated cost effective multiple cashew cutting machine (initial stage)

Fig4.15 Fabricated cost effective multiple cashew cutting machine (final stage)

34
4.5 ADVANTAGES AND LIMITATION

ADVANTAGES

Cost-Effectiveness: Compared to fully automated machines, a manual

multiple cashew cutting machine typically incurs lower initial investment costs,
making it more accessible to small-scale processors or those with limited
budgets.

Flexibility: Manual operation allows operators to adjust cutting

parameters and accommodate variations in cashew nut sizes or processing
requirements easily. This flexibility can be beneficial in handling different
batches or grades of cashew nuts.

Ease of Maintenance: Manual machines often have simpler designs and

fewer moving parts, resulting in easier maintenance and repair procedures. This
can reduce downtime and maintenance costs, contributing to overall operational
efficiency.

Suitability for Small-Scale Operations: Manual machines are well-

suited for small-scale cashew processing units or artisanal operations where
production volumes may not justify the investment in fully automated
equipment. They offer a practical solution for processing smaller batches of
cashew nuts.

Skill Development: Operating a manual machine requires hands-on skills

and expertise, providing opportunities for employment and skill development in
cashew processing communities. It can serve as a valuable training tool for
individuals entering the industry.

35
LIMITATION

The multiple cashew cutting machine may face challenges when used on
uneven or unstable surfaces such as rough terrain or soft ground. It is crucial to
ensure that ground provide sufficient stability to prevent instability during use.

Corrosion: This machine is often used in outdoor areas and is thus

exposed to air. It causes corrosion, but this can be easily prevented by applying
paint to it.

Wear of pressing blade: Adequate usage of this machine will definitely

cause wear to the pressing blade, and this can also be overcome by easily
grinding with the grinders that have abrasive material on them to sharpen them.

Processing Speed: While cost-effective multiple cashew cutting

machines offer improved efficiency compared to automatic methods, they may
still have limitations in processing speed when compared to fully automated
high-capacity machines. This could potentially lead to bottlenecks in production,
particularly in larger-scale processing facilities.

Regulatory Compliance: Compliance with safety and regulatory

standards may pose challenges, particularly in regions with stringent
requirements for food processing equipment. Ensuring adherence to standards
related to hygiene, worker safety, and product quality adds complexity and
potential costs to the implementation of multiple cashew cutting machines.

36
4.7 GENERAL APPLICATIONS

Low capital companies: This machine was developed solely for the very
small-scale companies in the village sector and rural sector who want to thrive
in the cashew processing sector.

Home Use: This machine may also be used at home since it does not
require any large input energy, such as electricity, and can complete the machine
process right at home.

Very Small-Scale Cashew Processing Units: Small-scale or artisanal

cashew processing units can adopt this machine to improve their processing
capabilities, enabling them to compete more effectively in the market. Its cost-
effectiveness and scalability make it suitable for facilities with limited resources.

Agricultural Machinery Manufacturers: Companies specializing in

agricultural machinery can incorporate similar design principles and
technologies into their product lines, catering to the needs of the cashew
processing industry and other sectors requiring similar cutting processes.

Export and Trade: Improved efficiency and quality assurance resulting

from the adoption of this machine can enhance the competitiveness of cashew
products in the global market. This could lead to increased exports, benefiting
both producers and economies reliant on cashew production.

Technology Transfer Programs: International development agencies

and technology transfer programs can promote the adoption of this machine in
cashew-producing regions, contributing to poverty alleviation, job creation, and
economic development through improved agricultural processing practices.

37
 CHAPTER V
RESULT AND CONCLUSION

The culmination of efforts in developing the cost-effective multiple

cashew cutting machine has unveiled a groundbreaking solution poised to
redefine the landscape of cashew processing for those who have very small and
medium scale cashew processing company and for those who have very low
capital and Through meticulous research, innovation, and engineering, this
project has yielded results that underscore the machine's potential to
revolutionize the cashew industry. Testing and evaluation have confirmed the
machine's efficiency and revealing several key outcomes.

Foremost among these is the significant enhancement in cutting efficiency

compared to traditional methods which is shelling the roasted cashew by beating
it with bare hands with the help of metal cuboid. By incorporating manual
processes and leveraging precise cutting mechanisms, the machine demonstrates
a remarkable increase in productivity.

Additionally, the cost-effectiveness of the machine stands as a testament

to its accessibility and affordability. Utilizing readily available materials and
components, it has been developed at a fraction of the cost of conventional
cashew cutting equipment in the market.

This affordability not only makes the machine accessible to small-scale

processors but also promotes economic sustainability within the industry. As a
result, cashew processing operations can now be conducted more efficiently and
cost-effectively, driving competitiveness and profitability in our society.

38
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