CHAPTER - 1

INTRODUCTION

1.1 INTRODUCTION

The chaff cutter is a simple but indigenous device, used for cutting straw, chaff, hay

and other green/dry fodder into small pieces before being mixed together with other forage to

feed animals. It provides very uniform length of cut of fodder. By the use of the chaff cutter,

animals are therefore induced to consume a much larger proportion of fodder with their food,

which not only improves the condition of the stock, but saves time in feeding. The main parts

motor, shaft, frame, rotating blades, bearings, v-belt, pulleys.

A majority of rural household irrespective of their socio-economic status and having

cattle own a chaff cutter, which is usually operated twice daily for chopping the fodder.

Family members, including children, perform the operation and the equipment is easily

accessible to children for playing. Due to large availability of chaff cutters, the associated

problems, particularly injury to the operator, are also numerous. As per the survey of

agricultural accidents, the chaff cutter caused maximum accidents and resulted in various

kind of injuries viz. permanent loss of upper limbs, fingers, hand and arms, fractures, cut and

other multiple injuries. In an epidemiological study, Mohan et.al.(2004) showed that in north

India children below 14 years of age were involved in 16% of all agricultural injuries. 30% of

all the equipment related injuries among children below 14 year old were caused by fodder

cutting machines. In children below 4 year, 50% of injuries resulted from these machines.

Ergonomics is also known as man-machine-environment system. The goal of ergonomics is

to design workplace to conform to the physiological, psychological and behavioural

capabilities of workers. Anthropometry is the technology of measuring various human

1
physical traits, such as body dimensions of workers and their strength. It is an effort to apply

such data to equipment and workplace design to enhance the efficiency, safety and comfort of

the operator Pheasant (1986) and Reobuck et.al. (1975).

Detailed anthropometric survey in India is important as the body dimension of India

population varies from region to region (Majumder, 1972). There is much more difference in

body dimension between Western and Indian population, as they vary trum region to region.

Anthropometric survey of western, northern, central and southern India has been reported by

Sen (1964), Gupta (1983), Gite and Yadav (1989), Frenalandez and Uppugondri(1992).

The development of safety gadgets for chaff cutters will help in reducing number of

accidents, sufferings and drudgery involved in chaff cutting the fodders and also enhances the

safety of workers. The data of male and female subjects may be used for modified chaff

cutter for them. Mismatches between human anthropometric dimensions and equipment

dimensions are known to be a contributing factor in decreased productivity, discomfort,

accidents, biomechanical stresses, fatigue, injuries, and cumulative traumas. Therefore,

various researchers have pointed out the importance of using relevant anthropometric data for

modification of chaff cutter.

Looking to the importance of the chaff cutter and problems associated with the

existing chaff cutter, this study is planned to refine the design of chaff cutter and introduction

of safety gadgets, which will help in reducing the number of accidents, sufferings and

drudgery involved in chaff cutting and also enhancing the safety of workers. The study was

taken up with the following objectives

 To evaluate the existing manually operated chaff cutter from ergonomic and

safety point of view.

2
  Design modification of chaff cutter to enhance safety and reduce fatigue of

workers.

 To evaluate the modified chaff cutter.

1.2. OBJECTIVE

To modify the design of chaff cutting machine which can allow the farmer to not only

cut the sugarcane in a form which can be utilized as a fodder for animal but can also various

feeding materials such as dry corn straw, grass, soybean, wheat stalk, with ease and thus

reducing the manual work of farmer and increases the fodder production.

1.3. TYPES OF CHAFF CUTTER

On the basis of cutting mechanism, the chaff cutter shall be of following types

a) Fly wheel type, and

b) Cylinder type.

On the basis of cut-chaff dropping position, the chaff cutter shall be of following types

a) Let-fall type

b) Throw-away type, and

c) Blow-up type.

d) The basis of feed

e) Conveyor-fed.

1.4. TERMINOLOGY

1.4.1. Fly wheel type: A chaff cutter is having rotating fly wheel with blades.

3
1.4.2. Cylinder type: A chaff cutter is the cutting mechanism in which it consists of rotating

cutting cylinder.

1.4.3. Let fall type: A chaff cutter is that in which the cut fodder is dropped down to the

bottom of the chaff cutter.

1.4.4. Throw way type: A chaff cutter is that in which the cut fodder is thrown away to the

front ward of the chaff cutter.

1.4.5. Blow up type: A chaff cutter is that in which the cut fodder is blow up through the

blow-up pipe.

1.4.6. Chute fed chaff cutter: A chaff cutter is that in which the feeding of the fodder crop

is done through a chute.

1.4.7 Conveyor fed chaff cutter: A chaff cutter is that in which the feeding of the fodder

crop is done through a conveyor.

4
 CHAPTER-2

LITERATURE REVIEW

Several studies have been carried out for batter performance of chaff cutter, reduction

of injuries by adoption of various safety parameters, parts. In this chapter the reviews

collected from different sources on various aspects of the present study have been presented

as follows

2. 1. Needs of chaff cutting

2.2. Accident with chaff cutter

2.3. Ergonomic and anthropometry

2. 4. Postural change during the farm activities

2. 5. Physiological parameters and energy expenditure of farm activities

2.6. Chaff cutter performance

2.1 NEEDS OF CHAFF CUTTING

Bhargrave et al. (1988) reported that the un-chopped straw would provide complete

choice for the animal to selectively consume more digestible parts and leaving behind the less

digestible parts, which consequently leads to substantial feed wastage. In addition the animal

might need to spend more energy for chewing the unchopped straw, than the chopped straw

(Chander, 2011).

Dikshit and Birthal (2010) estimated the feed consumption rates for different

livestock species by age-group, sex and function at the national level, as well as demand for

different types of feed by the year 2020. According to this study, by 2020 India would require

5
a total 526 million tonnes of dry matter, 855 of green fodder and 56 of concentrate feed

(comprising 27.4 Mt of cereals, 4.0 Mt of pulses, 20.6 Mt of oilseeds, oilcakes and meals and

3.6 Mt of manufactured feed). In terms of nutrients, this translates into 738 Mt of dry matter,

379 Mt of total digestible nutrients and 32 Mt of digestible crude protein. The estimates of

demand for different feeds will help the policymakers of the country in designing trade

strategy to maximize benefits from livestock production.

Tiwari and Kumar (2011) studied that fodder chopping is done mainly to save storage

space, to aid in curing to make the fodder more palatable, to facilitate uniform mixing of

concentrates and also to keep the fodder free form spoiling while in storage. The machines

used for chopping fodder are called chaff cutter or ensilage cutter or silo filler.

2.2 ACCIDENT WITH CHAFF CUTTER

Rawal (1984) studied that in Punjab, the human factors were associated with

agricultural implement injuries in 73 per cent of cases. These included in attentiveness,

wearing of loose garments, overwork and physical in capability.

Kumar and Anjali (2004) reported that the chaff cutter caused accidents about 7.8%.

The hand tools related injuries (8% of the total accidents) were non-fatal in nature. Due to the

lack of technical capability of the local artisans, adhering to safety and design standards is

impractical for the implements fabricated in the rural areas. The analysis emphasizes that the

effective safety and health management.

Mohan et al. (2004) reported that the fodder cutter machines were used every day by

farmers and their families in India for preparation of fodder to feed the livestock they own.

An epidemiological study done in North India showed that all age groups sustain fodder

cutter injuries while operating the machine. A detailed study of injuries and machine

6
characteristics resulted in a safer fodder cutter design. The design changes cost effective and

can be incorporated, in both existing and new fodder cutter machines. This paper reported the

process of the community based study and the safer design features of fodder-cutter machine.

Kumar et al. (2012) conducted a survey in five villages of Ghaziabad district of Uttar

Pradesh (a northern state of India) to determine the causal factors responsible for chaff cutter

injuries. It was observed that major injuries were caused during children playing with the

machine and workers feeding the fodder in to the chute. Based on the survey results and

mechanism of injuries, three safety interventions were developed to prevent the injuries.

These interventions can be retrofitted on old machines and can be incorporated in new

machines as well. Experiments were conducted using different fodder crops to observe

difficulty in chaff cutting with the safety interventions. It was observed that incorporation of

the interventions had no effect on performance of chaff cutting operation. These were

retrofitted on existing machines at different locations and the response was very positive.

2.3 ERGONOMIC AND ANTHROPOMETRY

The study of people and their relationship with the environment around them.

When anthropometric data (measurements/statistics) is applied to a product, e.g.

measurements of the hand are used to design the shape and size of a handle, this is

ergonomics. Anthropometrics applied.

Murrel (1979) stated that ergonomics is the scientific study of the relationship

between man and his working environment. The goal of ergonomics is to design the task so

that its demand stays within the capacities of workers. Its object is to increase the efficiency

of human activity by removing those features of design which are likely to cause inefficiency

or physical disability in the long term and thus to minimise the cost of operation. He further

7
stated that, to achieve maximum efficiency a man machine system must be designed as a

whole.

Klamklay and Sangkhapong (1990) collected anthropometric dimensions of Thailand

university students. The average age height, and weight of the female subjects was 19.98

years, 156.90 4.85 cms, and 49.84 7.50 kgs, respectively. The average age, height, and

weight of male subjected was 20.80 1.34 years, 169.17 5.60 cms, and 59.65 8.49 kgs,

respectively. Body weight and a set of thirty-eight body dimensions were measured. Several

dimensions obtained from the lower-southern population appear to be different from the data

recently collected from other regions of Thailand. The current Thai population appears to

have greater height and weight than the Thai population of the 1980s and 1990s, but still

smaller than the adults from the US and Norway in all selected dimensions.

Kar et al. (2003) suggested the use of hand anthropometry data which can help in the

proper designing of equipment for better efficiency and more human comfort. Eight hand

dimensions had been identified which were considered more useful for designing agricultural

hand tools. A right and left hand dimension were collected among 200 male and 204 female

workers of West Bengal and eastern India. It was noted that there were significant differences

(P<0.001) in hand measurements between the right and left hands as well as between right

and left hands as well as between male and female workers. However, the percentages of

differences in the measurements right and left hands was small (0.10 % to 3.49%) than those

between the men and women (7.1 % to 11.96 %) percentile value (5th, 50th, 95th) of the

anthropometric dimensions were computed separately for men and women. The hand

dimensions of the subjects of present study were compared with the farmers of central part of

India. Some proportions of hand dimensions were also computed.

8
 Nag et al. (2003) studies the hand breadth, circumference and depth and found that

they were normally distributed, with some deviation in case of the finger lengths. Hand

length was significantly correlated with the fist, wrist and finger circumferences. The fist and

wrist circumference, in combination, was better predictors of the hand length. The hand

lengths, breadths and depths, including finger joints of Indian women studies were smaller

than those of American, British and West India women. The hand circumferences of the

Indian women were also smaller than the American women. The handgrip strengths of the

present women were much less (20.36 ) were less than those of American, British and west

Indian women. Grip strength was found to be significantly correlated with three hand

dimensions (6, 18, 48). Grip strength of India women (20.36 ) were less than those of

American, British and West India women. The women who are forced to frequently use

cutters, strippers, which are not optimally designed to their hand dimensions and strength

range, might have higher prevalence of clinical symptoms and disorders of the hand.

2.4 POSTURAL CHANGE DURING THE FARM ACTIVITIES

During the operation by manually operated chaff cutter the problem of workers who

rotated the flywheel, continually chaffing in the standing and bending position. Which affect

the change of position helps in providing extra force to optimum chaffing as well as creates

more facility to the operator. Locking to the above some of review was undergone and

presented below.

Vos (1973) noticed that substantial increase in workload in the bending position

occurs when the working level is lower than the level of the feet. The work is to be carried

out on the ground itself the squatting position seems the most favourable.

Sawkar (1999) revealed that the handling of tools, multiple postures adopted to

perform the activity with lots of twists and turns, the forceful torque movements, the stature

9
content involved in holding the posture to perform the activity. Further, the author revealed

that, squatting in forward bent posture to harvest the wheat crop was more strenuous than

bending in cutting the crop. However, bending was more strenuous than the standing posture

in harvesting of jowar crop.

Borah and Kalita (2002) concluded that combination of standing and bending

postures were generally used by most of the farm women for performing cutting (89%),

threshing (37%), storage (45%) and sun drying of grains (56%) respectively. Squatting and

bending postures were adopted for soaking and preparing the seed for sowing (57%) and

preparing threshing yard for threshing (74%). Only bending postures were used for uprooting

of seedlings (95%) and transplanting (96%). Sitting posture was used for winnowing (92%),

sieving (95%) and cleaning (96%) by majority of the farm women for performing the farm

activities.

Singh et al. (2012) developed setup which had a provision for attaching on-line torque

transducer. Variable crank length was provided that could be adjusted as per the farm women

(workers). The setup had also a provision for rising up and down to match workers’

conditions. Isometric torque was measured at each quadrant positions of handle (0°, 90°, 180°

and 270°) at different crank lengths (17.5, 21, 24, 27 and 30 cm). Higher torque was

developed by farm women in standing posture as compared to sitting. The crank length up to

27 cm gave better torque at nearly all positions. The lowest torque may be considered for

designing the equipment amongst all positions of handle so that human being could easily

operate the equipment.

10
2.5 PHYSIOLOGICAL PARAMETERS AND ENERGY EXPENDITURE OF FARM

ACTIVITIES

According to gross et.al (1973) feeling of comfort or discomfort results from the use

of muscles and skeleton; posture as well as body movements. Comfort is often but not always

coordinated with the amount of energy expended. That is less energy expenditure with greater

comfort, the more with discomfort.

Grandjean (1973) observed extensive use of heart rate as a measure to know the

extent of stress particularly under static conditions. According to him, heart rate within

certain limits rises in direct proportion to the energy expenditure.

Ganguly and Datta (1975) obtained a highly satisfactory linear relationship between

energy expenditure and peak heart rate in lower extremity amputees and in normal control

subjects, during different teat activities. They also suggested an equation for predicting

energy cost.

E=0.068, PHR=4.59.

Where, E= Energy expenditure in Kcal/min,

PHR = Peak heart rate in beats/min.

Saha (1976) obtained a highly satisfactory linear relationship between energy

expenditure and working heart rate from data of field studies. He also derived a

Regression equation for predicting energy expenditure of men of 58 kg body weight from

working heart rate. E (Kcal/min.)=0.0695 PHR (beats/min)-4.332.

Nag et al. (1980) reported that the average work pulse rate ranged from 180 to 153

beats/min in different agricultural work. However, for a large number of operations cardiac

11
responses were less than 130 beats / min, which was considered as a moderate level of

workload of work. Only water lifting and pedal threshing operations required 153.3 and 140.3

beats/min. respectively. The oxygen uptake at the pulse rates of 120, 130, 140, 150 and 160

beats per min correspond to 43, 48, 55, 61 and 74 per cent of maximal oxygen uptake from

120-150 pulse beat /min, the relative load of work increased by about 5-7 percent of maximal

oxygen uptake for every increment of 10 pulse beats per minutes.

Further, the authors have reported that by fixing the oxygen uptake, it is also possible

to arrive at 120-132 beats/min., representing a moderate level of activity. The total daily

energy expenditure of the group of agricultural workers varied from 10.3 to 11.7 MJ of which

53 to 56 per cent of the total energy, i.e. about 5.6 to 6.6 MJ was expended during a working

day, while the time weighted average of the whole day activities amounts to 7.2 to 8.1

kg/min. (i.e. the relative load was only around 20.22 per cent of maximal oxygen uptake),

whereas, if the working day energy expenditure only is taken into account, the time weighted

average demand was around 10.9 to 14.6 kg/min (i.e. about 30 to 40 percent of maximal

oxygen uptake).

Chauhan and Saha (2004) conducted a study on acceptable limits of physiological

workload for physically active Indian women. Assuming that Indian women can sustain

physical activity for long duration with a Relative Load (RL) 35 per cent without

physiological strain and undue fatigue, an attempt has been made to determine the acceptable

limits of physiological workload based on the relationship between Energy Expenditure (EE)

and RL and between EE and belonging to three different age groups,viz: 21-30, 31-40 and

41-50 years, having body weight ranging from 33 to 55 kg, employed in the job of manual

sweeping of railway platform. The acceptable limits of heart beats were worked out to be 110

beats/min, 95 beats/ min and 100 beats/min respectively for different age groups, and the

corresponding values of energy expenditure to be 10KJ/min, 9.6KJ/min and 10.5KJ/min,

12
respectively. The difference though not significant, could be attributed to influence of age,

body built, and level of physical fitness (VO2 max), all of which would modify physiological

workload.

Kwatra et al. (2010) have studied the ergonomic evaluation of paddy threshing

activity revealed that the physiological responses and physiological cost of work reduced

significantly by using paddy thresher (manually operated). The HR work, ODR, ERR, and

physiological cost of work reduced from 154.5 to 122.5 beats/ min, 4.6 a score of 3.7, 17.64

to 12.80 kJ/min and 131 to 52.03 respectively when comparative study was undertaken

between manual beating of paddy on drum and the use of paddy thresher (manually

operated). The increase in Heart Rate per kg of grain threshed reduced significantly contrary

to reduction of ΔHR work by 20.71 percent.

Kumar et al. (2010) conducted experiments to determine the human energy

expenditure in operating a manual chaff cutter. Three operators of different age groups were

selected for the experiments. Calibration was done for all the three operators on bicycle ergo

meter and calibration equations were determined. There was increase in energy expenditure

with increases in feeding rate. Oxygen consumption was much higher than the sustainable

level of 35% max for all dry and green fodder. Specific energy increased with increased in

diameter of stalk. Specific energy also varied with material and was lower in case of dried

material of similar diameter. There was mismatch between the energy expenditure by an

operator and the energy requirement for cutting of the crops for sustainable operation.

2.6 CHAFF CUTTER PERFORMANCE

Yadav et al. (2010) found that strength parameters play a significant role in design of

manually operated push-pull type equipment. Average strength of both hands in standing

posture for male and female workers was found to be 209.93 and 117.72 N-m respectively

13
which can be used in the design of manually operated equipment like chaff cutter. Torque

strength of preferred hand in sitting posture and hand grip torque worked out in this study for

both male and female workers were found very much useful in design of hand controls such

as steering, knobs, etc. These strength parameters are found to play a significant role in

design/ modification of hand controls and foot controls on different workplaces of machines.

The machine workplaces designed on strength parameter data were found to greatly enhance

the operator’s comfort, safety and efficiency as well.

14
 CHAPTER-3

CONSTRUCTION AND WORKING

This chapter deals with materials, methodology and working followed, which include

study of existing chaff cutter and modification of chaff cutter as per ergonomic consideration

and its evaluation. The various factors which govern the modification of chaff cutter are

ergonomic consideration, availability of sources, operational safety, power requirement, and

cost of operation, availability of spare parts and ease of operation. In this study an effect has

been made to kept operation and adjustments quite simple and easy so that farmers can use it

without much knowledge.

3.1 METHODOLOGY

3.1.1) Problem detection in chaff cutting process – The existing machines are observed and

studied properly to detect the problems faced by the user.

3.1.2) New cutting technology – The research work in this domain was studied and new

methods were developed to achieve desired goal.

3.1.3) Single phase operation – The power supplied to machine is single phase so to make it

easy to operate at any location.

3.1.4) Safety – Highest priority is given to safety of the operator.

3.2 BASIC FUNCTIONAL PARTS OF MINI CHAFF CUTTER.

1. Main frame.

2. Feeding hopper.

15
 3. Cutting unit.

4. Casing and Discharge unit.

5. Power unit.

6. Power transmission unit.

7. Bearings

8. Rotating shaft

9 .v-pulleys

3.2 .1.MAIN FRAME

The foundation frame was main supporting structure. An angular shaped main frame

made up of M.S. angle. On main frame front side head unit mounted and other side two

bearing placed with the help of nut bolts for cutting unit shaft. Another two angles welded to

both sides of main frame. On bottom angles of main frame, the platform made for electric

motor and provision made for up and down movement to keep proper tension on belt. The

height of foundation frame maintained in such way that, it should ergonomically suite to

facilitate easy feeding of fodder in to the hopper.

Fig (3.1) Main frame

16
3.2.2. FEEDING HOPPER:

The hopper should make up of M.S. sheet. The hopper should have mounted on head

unit side plates by nut bolts and it has sufficient volume and inclination. It directly feed the

fodder in to the drum. Proper provision should made between mouth and hopper to avoid

clogging at the feeding end of hopper.

Fig (3.2) Feeding hopper

3.2.3. CUTTING UNIT:

The cutting mechanism of chaff cutter cutting unit with blades. The cutting unit

should made up of High carbon steel. When the fodder material comes in contact with fixed

and rotating blades the blades cut the fodder in to required pieces by the action of impact and

shearing and at the same time it passes to the discharge unit with the help of removing the

sieves.

Fig (3.3) cutting blade

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3.2.4 .CASING AND DISCHARGE UNIT:

The Casing and discharge unit of circular shape should made to front of main frame

by lower cover and welded to it. The semicircular cover should provide to discharge unit. The

provision made for cover to open according to chaff fall as per requirement.

Closed (casing) open (casing)

Discharge unit

Fig (3.4) casing and discharge unit

3.2.5. POWER UNIT:

18
 An electric motor is an electrical machine that converts electrical energy into

mechanical energy. Most electric motors operate through the interaction between the motor's

magnetic field and winding currents to generate force in the form of rotation.

In this chaff cutter 2HP, single phase electric motor is used. To this electric motor

pulley is fixed at one end, which is connected to rotating with the help of flat belt

Fig (3.5) motor

3.2.6 POWER TRANSMISSION UNIT:

A belt is a loop of flexible material used to link two or more

rotating shafts mechanically, most often parallel. Belts may be used as a source of motion,

to transmit power efficiently or to track relative movement. Belts are looped over pulleys and

may have a twist between the pulleys, and the shafts need not be parallel.

Fig (3.6) v-belt

19
 The cutting unit of chaff cutter gets power through proper belt pulley arrangement

having 2 HP electric motor fitted on chaff cutter for power transmission to cutting and

feeding unit.

3.2.7. BEARINGS

A bearing is a machine element that constrains relative motion to only the desired

motion, and reduces friction between moving parts. The design of the bearing may, for

example, provide for free linear movement of the moving part or for free rotation around a

fixed axis; or, it may prevent a motion by controlling the vectors of normal forces that bear

on the moving parts. Most bearings facilitate the desired motion by minimizing friction.

Bearings are classified broadly according to the type of operation, the motions allowed, or to

the directions of the loads and forces applied to the parts.

A pillow block is a pedestal used to provide support for a rotating shaft with the help

of compatible bearings & various accessories. Housing material for a pillow block is typically

made of cast iron or cast steel.

Fig:(3.7) Pillow block bearing

3.2.8. SHAFT

Shaft is a rotating machine element, usually circular in cross section, which is used

to transmit power from one part to another, or from a machine which produces power to a

20
machine which absorbs power. The various members such as pulleys and gears are mounted

on it.

Fig: 3.8 shaft

3.2.9. V-PULLEY

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

change of direction of a taut cable or belt, or transfer of power between the shaft and cable or

belt. In the case of a pulley supported by a frame or shell that does not transfer power to a

shaft, but is used to guide the cable or exert a force, the supporting shell is called a block, and

the pulley may be called a sheave. A pulley may have a groove or grooves

between flanges around its circumference to locate the cable or belt. The drive element of a

pulley system can be a rope, cable, belt, or chain.

Fig: 3.9 v-pulleys

21
3.2.10 POWER REQUIREMENT:

The chaff cutter should firmly fixed on level and hard surface. The clearance

between fixed blades should set and other adjustments should made in accordance with the

development. The chaff cutter should attached to the electric motor then chaff cutter should

run about 60 minute and power requirement should calculated by following formula.

3.3 CONSTRUCTION OF MINI CHAFF CUTTER

Experimental setup and construction of mini chaff cutter, first off all make the

rectangle frame with required dimensions and select required motor and it is placed middle of

the rectangle frame at bottom of the frame after that bearings placed on the top of the frame

these are fitted with bolt and nut after that shaft is fixed between two bearings and other of

the frame where cutting process is form after that casing is placed other side of the frame at

the end of the shaft fixed the cutting blade with help of bolt and nut , pulleys are fixed to the

shaft and another pulley is fixed to the motor after that fitted the belt between two pulleys ,

give the connections to the motor with electrical wires these are sealed with gum tape.

Fig: 3.10 (construction of mini chaff cutter)

22
3.4 WORKING OPERATION OF MINI CHAFF CUTTER

Chaff cutter machine for feed is powered by electric motors, drive main shaft, Main
shaft is connect to the motor through belt system When the material enter the feeding
hopper roller then the stalk is cut into cutting institutions at a certain speed enter the cutting
part, approved by high speed rotating cutter cut up after the through the material outside.
Power Operated chaff cutter consist a electric motor which is 2HP, or 1HP as per required,
three phase or single phase and Starter is required three phase only. A flat belt (leather) is
connected to shaft pulley and motor pulley through which the cutting blade will rotate. When
power supplied, the motor will starts, then the shaft rotates through a flat belt. At the same
time the number of stalk pieces feeds through a tin sheet metal hopper. The stalks through
hopper which the contact to the Blades with the help of inclination of the hopper system.
Then the chaff will cut into small piece, it will helpful for cattle.

Fig; 3.11 (different views mini chaff cutter)

23
 CHAPTER-4

OBSERVATION

4.1 SPECIFICATIONS OF MINI CHAFF CUTTER

Table no 4.1

Power source 1HP, single phase electric motor, 1420rpm

Colour of machine Smoke gray and Red

Blade
Number of blades 2
Size of the blade 300×60 mm
Blade material High carbon steel
Power transmission system
Number of pulleys 2 pulleys, one shaft pulley and motor pulley
Size of the pulleys Shaft pulley 75mm and motor pulley 70 mm diameter

Type and size of belt
Bearings and number
Frame material
Size of the frame
Material of shaft
Size of the Shaft
Casing , hopper and discharge unit
Size and material of casing
Size and material of feeding
Textile B-type and v-belt and 40inches
2 pedestal bearings and P-205
Frame
M.S. Angle plate
635×500×500mm
Shaft
Mild Steel
25diameter and 400 mm length
400mm diameter and M.S sheet
150mm diameter 200mm length , M.S sheet

hopper
Discharge unit 100mm × 60mm and M.S sheet

4.2 FORAGE STALKS USED FOR FEEDING ANIMALS

Forage is a type of grass or legume used to feed cattle in many different forms. The

most common are grass in the pasture, corn silage and alfalfa bailed for hay or chopped

24
as silage. Grass: Plants typically have narrow leaves; hollow, jointed stems, and flowers that

top the plant that become seed heads.

 Average diameter of the forage stalk = 25mm

 Single forage stalk cutting force required taken as per previous articles for 10 mm

diameter stalk= 0.2 N

CHAPTER -5

CALCULATIONS

 power of the motor

1HP = 746watts

2× π × N ×T
Power (p)¿
60 ×1000

Where,

25
 P= power of the motor

Hp= Horse power

N= Motor rpm

T= torque, N-m

F= force

R= radius of the blade

 Torque required to cut the forage stalk

2× π × N ×T
P¿
60 ×1000

2× π ×1420 × T
0.746 ×10 3=
60 ×1000

Torque (T) = 5016.74 N-mm

Torque(T)= 50.1674 N-m

 Total force required cut the forage stalks

Torque (T ¿=Force × radius of blade

5016.74=Force× 150

Force = 33.44 N

 Force required for cutting single forage stalk as per have taken previous articles

For 10mm diameter stalk =0. 2 N

 Average diameter forage stalk have taken = 25 mm

 One single stalk cutting force required = 25×0.2

= 5N

 Total cutting force = cutting force required for single stalk × Number of stalks

Total cutting force

Number of stalks=
Cutting force required for simgle stalk

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 33.44
Number of stalks=
5

=6.68 ≅ 7

Number of stalks kept in to hopper =7

CHAPTER-6

ADVANTAGES AND DISADVANTAGES

6.1 ADVANATAGES

 Chaff Cutter has compact structure.

 Equipped with safety device. Reliable and safety.

 Compact structure simple operation and installation.

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  Chaff cutter has long service life.

 Skilled persons are not required.

 For operating manually more energy is not required.

 Chaff cutter is easily portable.

 Low maintenance cost.

6.2 DISADVANTAGES

 High power consumption.

CHAPTER-7

APPLICATIONS

 Dairy farms: In dairy farms it is used to cut the chaff, dry grass, green grass at a very

large scale.

 Farm fields: Farmer uses the chaff cutter for cutting the chaffs and other things

which are to be feed to the domestic elements.

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 Animal food processing industries: Now a day, there are industries which

manufacture food for animals through this chaff; there also this chaff cutter is used.

CHAPTER-8

RESULT

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 CHAPTER – 9

CONCLUSION

 We have replace different sources of chaff cutter by 1 H.P single phase which

require low electricity & easily available anywhere so it’s beneficial to farmer.

 By using different types of blades we can obtain different types of chaff for animal.

 By using this machine we can cut the sugarcane waste so that it can be utilized as a

fodder for animal as well as grind various feeding materials such as dry corn straw,

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 grass, soya bean, wheat stalk, with ease and thus reducing the manual work of farmer

and increases the fodder production.

 Implementation of technology in the field of agriculture has brought a very wide

changes in manual procedures are replaced by advanced technical procedures. Here

before we used to cut the chaff, grass manually to be feed the animals. When it was in

a very large scale it is difficult to cut and time consumes more. Due to in the chaff

cutter, chaff can be easily cut in a very least time and helps avoiding injuries because

through manual chaff cutter, we can get injuries. So technology has brought a wide

change in the field of agriculture.

CHAPTER – 10

REFARANCE

REFERENCE BOOKS

1. Theory of machine, R.S.Khurmi-Gupta.

2. Machine design element, V.B. Bhandari.

3. Machine tool& design, N.K.Mehta.

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REFERENCE

 International Research Journal of Engineering and Technology (IRJET) on power

operated fodder chaff cutter.

 International Journal of Agriculture Sciences ISSN: 0975-3710&E-ISSN: 0975-9107,

Volume 10, Issue 6, 2018, pp.-5517-5521. Available online at

http://www.bioinfopublication.org/jouarchive.php?opt=&jouid=BPJ0000217.

 Anonymous (2003) 17th Indian Livestock census, Govt. of India

 Anonymous (2015) 21th Indian Livestock census, Govt. of India

 Marey, S.A., Drees, A.M., Sayed-Ahmed, I.F., and. ElKeway, A.A. 2007.

Development A Feeding Mechanism Of Chopper For Chopping Sugarcane Bagasse.

Misr J. Ag. Eng., 24(2): 299-317.

 Barrinton, G.P., Berge, O.I. and Finnor, M.F. 1971. Effect of using a recutter in a

cylinder type forage harvester for choppinglow moisture grass silage. American

Society of Agricultural Engineers., 14 (2): 232-233.

 Hennen, J.J. 1971. Power requirements for forage chopping. American Society of

Agricultural Engineers. 71- 145.

 P. B. Khope, J. P. Modak, Development and Performance Evaluation of a Human

Powered Flywheel Motor Operated Forge Cutter, International Journal of Scientific &

Technology Research, Volume 2, Issue 3, March 2013.

 Ismail Fouad Sayed-Ahmed, El-Desoukey. N, and ElNagar. A.B. 2009.

Development Of A Chopping Machine For Agriculture Residue (a Case Study on

Grape Trashes), Agricultural mechanisation in Asia, Africa, and Latin America,

40(1): 13-24. [6]. P.B. Khope, J.P. Modak, Establishing empirical relationship to

predict the chaff cutting phenomenon energized by human powered flywheel motor

(hpfm).

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