Date:

1-4-20

The University of Jordan

School of Engineering
Mechanical Engineering Department
Machine Design 2

Hazel Nut Shelling Machine

PROF. SALIH AKOUR

STUDENTS NAME: RADWAN TAREEF #0167120
Introduction
Shelling and separation are one of the most important processes involved in the
production of hazel nut where shelling is the process of removing the nut kernel
from its pod without any damage effect by many actions just like compression
shearing and impact.
In this report I’m going to design and choose the main parts of this machine such
as shafts and bearings also analyze the applied forces on the gears in the simple
gear train system.
This machine is important in industries which responsible for producing nut’s. Its
operation depends on mechanical methods not the traditional one, this machine
can shell hazel nuts completely and separate shells and kernels purely without
any damage to the kernel.
Advantages and benefits:
 High efficiency.
 High shelling rate.
 Low damage rate.
 Easy to operate.
 Low energy consumption.
 Compact structure.
 Small occupation space.
 Save time and labor.
Experimental work
Due to medical and other circumstances I have not been able to use our
laboratory to find out the minimum force required to crush the shell of the
hazelnuts without cracking the kernel; But I did an experiment at home using a
group of books of known weights by placing them on the nut until cracks
Finally I have found that the value of the force needed to crush the shell without
any damage in the kernel has a value of 300 N.
To be more accurate this value is not correct by 100% due to experiment
conditions and other errors.
Also I have measured the average diameter of the nut using a roller and I found it
to be 15-17 mm.
About the clearance between the shell and the kernel it was hard to measure its
value but I assumed it to be 2-3 mm.

Mechanism Description
The first process in this machine is to introduce the nuts into the sizing
mechanism which consists of two cylinders rolling in opposite sides and have a
clearance between them has a value of the needed size of the nuts then the nuts
will be dropped into the shelling chamber which consists of a rolling rasp and a
stationery plate the shells of hazel nuts are chilled by the rolling force between
the rotating rasp and the stationery plate to ensure that the shell will receive the
proper forces the clearance between the shell and the kernel must be larger than
the deformation applied to it , and to separate the kernels from the shells they
will fall down to the air duct, and the fan (blower) blows shells out then the
kernels taken out alone in a container.
Design analysis

Assuming:
Normal Pressureangle ϕ n=20o

Helix angle ψ=30o

Gear parameters:

i. Gear 2 (Pinion)
Pt =6 teeth/ mm

N P=80 teeth

N 80 1
d= = =13 m m
Pt 6 3

Pt 6
P n= = =6.93 mm
cos ⁡(ψ ) cos ⁡(30)

P x =Pt tan ( ψ )=6 × tan ( 30 )=3.46 mm

1 1
Addendum= = =0.144 mm
Pn 6.93

1.25
Dedundum= =0.18 mm
Pn

Np 80
Pinion pitch diameter= = =13.33 mm
P n × cos ⁡(ψ ) 6.93× cos ⁡(30)
ii. Gear 3

Pt =6 teeth/ mm

N G =120 teeth

N 120
d= = =20 mm
Pt 6

Pt 6
P n= = =6.93 mm
cos ⁡(ψ ) cos ⁡(30)

P x =Pt tan ( ψ )=6 × tan ( 30 )=3.46 mm

1 1
Addendum= = =0.144 mm
Pn 6.93

1.25
Dedundum= =0.18 mm
Pn

NG 120
Gear pitch diameter= = =20 mm
P n × cos ⁡( ψ ) 6.93× cos ⁡(30)

Gear train analysis:

For gear 2 (pinion);

n P=1000 rpm

For gear 3;
nG N P
=
nP NG

80
nG =1000 × =667 rpm
120
Gear force analysis:

Analysis of Gear 3
As I mentioned earlier that the force applied on the gear due to
crushing the shell is 300 N, the machine will crush 10 nuts at the
same time so the value is 3000 N this force will be the tangential
component on the tooth so;

W t =3000 N

tan ⁡(ϕ n)
ϕ t=tan−1 ( )
cos ⁡(ψ )
=22.8o

The radial component;

W r =W t × tan ( ϕ t ) =3000× tan ( 22.8 ) =1261 N

The axial component;

W a =W t × tan ( ψ )=3000 × tan (30 )=1732 N

Analysis of the Pinion

Our simple gear train consists of two helical gears, the forces acting
on the pinion have the same values of that acting on the gear but
with opposite direction so;

W t =3000 N

W r =1271 N
 W a =1732 N

Power of electric motor

H H
W t= =
V πdn

H=3000 × π ×13.33 ×10−3 × 1000 ≈126 KW

Shaft and Bearing selecting:

Shaft #1
X-Y Plane:
B1Y
B2Y
2mm
2mm B1X

B2 B1
3000

1261

∑ M B 1=0
y
(−B 2 × 4 ) + ( 3000× 6.67 ) + ( 1261 ×2 )=0
B2y =5633 N

∑ F y =0
5633−1271+ B1y =0
B1y =−4362 N

∑ F x=0
x
B −1732=0
1
x
B =1732 N
1

X-Z Plane:

B2Z 3000 B1Z

 B2 ∑ M B 1=0 B1

( B2z × 4 )−( 3000 ×2 )=0

Bz2=1500 N

∑ F z=0
Bz1=1500 N
Resultant forces on bearing 1 & 2:

2 2
( F )B 1=√ ( 4362 ) + ( 1500 ) =4612 N
2 2
( F )B 2=√ ( 5633 ) + ( 1500 ) =5829 N

Bearing #1:
Assume F e =2000 N
1
109 3
C 10=2000× ( ) 106
=20 KN

From Table 11-1:

C 10=25.5 KN C 0=13.7 KN

F a 1732
= =0126
C0 13700
F a 1732
= =1.36>e
F r 1271

X 2 =0.56 Y 2=1.85

F e =( 0.56 ×1 ×1271 ) + ( 1.85× 1732 )=13.03 KN

C 10=13036 N

Selecting:
C 10=13.3 KN C 0=6.55 KN Bore=20 mm
Bearing #2:
F e =Fr =5829 N

C 10=19.43 KN

Selecting:
C 10=19.5 KW C 0=10 KN Bore=30 mm

Shaft #2
X-Y Plane:
B3Y
Y
B 4
B4X
2mm 2mm

B4 B3
3000

1271
∑ M B 3=0
(−B 4y × 4 )−( 1271 ×2 )−( 3000 ×10 )=0
B4y =−8135.5 N

∑ F x=0
B4y +1271+B 3y =0

B3y =6864.5 N

∑ F x=0
Bx4 −3000=0

Bx4 =3000 N
X-Z Plane:

B4Z B3Z

2mm 2mm

B4 B3

1000

∑ M B 3=0
( B ¿ ¿ 4 z × 4)− (3000 × 2 )=0 ¿

Bz4 =1500 N

∑ F z=0
1500+ B3z−3000=0

Bz3=1500 N

Resultant Forces on bearings B1 & B2:

2 2
( F r ) B 3=√ ( 1500 ) + ( 6846.5 ) =7009 N
( F a )B 3 =0
2 2
( F r ) B 4= √( 1500 ) + ( 8135 ) =8272 N
( F a )B 4=3000 N
Bearing #3:
F e =Fr =6846 N
1
10 9 3
C 10=6846 × ( )
106
=31.703 KN

Selecting:
C 10=3.2 KN C 0=18.6 KN Bore=45 mm

Bearing #4:
F e =X i V F r +Y i F a

Assume F e =3200 N
C 10=32 KN

Selecting from table 1-11:

C 10=33.2 KN C 0=18.6 KN

F a 1732
= =0.093
C0 18600

Using interpolation to find e:

e=0.224
Fa
=1.4 >e
VF r

X 2 =0.56 ; by interpolation Y 2=1.96

F e =( 0.56 ×1 ×1271 ) + ( 1.96 ×1732 )=1367 N

C 10=13.67 KN

Selecting:
C 10=14 KN C 0=6.95 KN Bore=25 mm

Hazelnut
As I mentioned earlier the clearance between the shell and the kernel has a value
of 2-3 mm also as we can see from figure 1 which represents the relationship
between the force applied on the hazel nut and the deformation of the shell due
to that force, we can see that the value of deformation is 1.18.
Since the value of deformation is less than the clearance
1.18<2−3

Then the kernel will not be damaged

Figure 1: Force VS Deformation of hazelnut

Friction force
Nut

FF FF

FN FN

Rollers
FF: frictional force between nut and rollers.
F F =μ F N

Where μ depends on the type and size of hazel nut.

∑ F x=0
F F cos ( ∅ ) + F N cos ( ∅ )−F F cos ( ∅ ) −F N cos ( ∅ )=0

Shaft stress analysis

Parameters of the shaft:
d=28 mm
D=42 mm
r =2.8 mm
M a=150 N . m

T m=125 N . m

Sut =735 MPa

S y =574 MPa

reliability =0.99
D
=1.5
d
r
=0.1
d

From figure (A-15-9) in the book

K t =1.68

From figure (A-15-8)

K ts =1.42

From figure (6-20)

q=0.85

From figure (6-21)

q shear =0.92

Using Eq.(6-32)
K f =1+0.85 ( 1.68−1 )=1.58

K fs =1+ 0.92 ( 1.42−1 ) =1.39

Eq.(6.8)
S'e =0.5 ( 735 ) =367.5 MPa

Eq.(6-19)
K a =4.51(735)−0.265=0.787

Eq.(6-20)
−0.107
28
Kb= ( )
7.62
=0.87
K c =K d=K f =1

Table 6-6
K e =0.814

Se =0.787 ( 0.87 ) 0.841 ( 367.5 )=205 MPa

Applying Eq.(7-7) for the DE-Goodman :

0.5 0.5
[ 4 (1.58∗150) ] [ 3 ( 1.39∗125 )2 ]
1
=
16
n π ( 0.028 )3 { 205∗106
+
735∗106 }
= 0.615

So,
n=1.56

From Eq.(7-5) and (7-6):

2 0.5
32∗1.58∗150
'
σ =
a
[(
π ( 0.028 )3 )] =104.4 MPa

2 0.5
16∗1.39∗125
'
σ =3
m
[(
π 0.0283 )] =69.4 MPa

For the yielding factor of safety determine an equivalent von Mises maximum
stress using Eq.(7-15):
2 0.5
32∗1.58∗150 2 16∗1.39∗125
σ 'max=
[( π∗0.028 3) (+3
π∗0.0283 ) ] =125.4 MPa
Sy
n y= =4.58
σ 'max
Detailed Design description
Pinion:
A pinion is the smaller of two mating gears it consists of 80 tooth with 6mm
transverse diametric pitch and 6.93 normal diametric pitch with angular speed of
1000 rpm and helix angle of 30O.
This pinion is connected to a gear and shaft connected to an electric motor.
Its function is to transmit motion and forces.

Figure 2: Pinion
Gear:
It consists of 120 tooth with a 13.33mm diameter and 6mm transverse diametric
pitch has an angular velocity of 667 rpm also it has a helix angel of 30 O.
This gear is connected to a pinion and shaft to crush the nuts.
Its function is to transmit motion and forces.

Figure 3: Gear

Bearing:
Bearings are one of the most important parts because their rolling motion make
almost all movements easier and they help reduce friction.
Bearings have three functions:
  They transfer motion.
 They support and guide components which turn relative to one another.
 They transfer forces.
As we can see from figure 4 which shows a ball bearing that I used in this
machine which contains 8 balls.

Figure 4: Bearing

The whole assembly:

 Figure 5: shelling machine

Discussion
This report shows the design and analysis of a shelling machine also its shows the
selection processes of specific parts such as bearing and shafts.
At first we should start by knowing the value of the force needed to crush the
outer shell of the hazel nut without any damage to the kernel then I did some
analysis on the nut and gears to know the pressure and torque needed to be
transmitted by the gears, shafts and electric motor.
About the bearings I have done some special analysis to select the proper bearing
to do its function perfectly without any failure at first I calculate the reaction
forces on the bearing in the two planes X-Y & X-Z, then I found the equivalent
force applied on each bearing because there is some bearings have combined
radial and thrust loadings. Furthermore, I found the values of C10 & C0 to go to
table 11-1 in the book and select the wright bearings.
Finally, I recommend using a cheap and easier way to sort the kernel and the shell
by using a barrel filled with water and after the shelling process end depending on
the density of the products of this process, they will fall in this barrel so the shells
will float on the surface of the water and the kernel will go down.
Conclusion
Finally, as I mentioned earlier that the deformation that will happen to the outer
shell of the nut is lower than the clearance between the shell and the kernel so
we can know that the kernel will not be damaged also I have shown during the
selecting of the parts that they will stand against the loads applied onto it.

References
 Mechanical Engineering Design Book.
 Research Gate.com
 Shelling machine.com
 Grin.com