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International Journal of Mechanical Engineering and Technology (IJMET)
Volume 8, Issue 11, November 2017, pp. 1020–1028, Article ID: IJMET_08_11_104
Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=11
ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication Scopus Indexed

REVIEW ON DESIGN AND OPTIMIZATION OF

THRESHER IN CROP CUTTING MACHINE
Rahul S. Warghane
Ph.D. Scholar, Department of Mechanical Engineering, Vellore Institute of Technology,
VIT University, Vellore, TamilNadu, India

Rajkumar E
Associate Professor, Faculty of Mechanical Engineering , Vellore Institute of Technology,
VIT University, Vellore, TamilNadu, India

ABSTRACT
In the present paper, an effort has been taken to perform a literature review on the
development in the mechanization of thresher in crop cutting machine. The harvesting
incurs about 30% cost of total production. In India, considerable R & D work for
design and development of agricultural implements and machinery for few operations
have been developed. However, the adoption of these implements and machinery has
not been up to the desired level. Thus there is a considerable mechanization gap.
Research and records have produced data for many individual segments within a total
harvesting system. However, to date, very few attempts have been made to numerically
optimize the overall system. The different machines and their process parameters are
studied and compared through the study.
Keywords: Crop Cutting, Design Optimization, Soya-bean crop, Thresher.
Cite this Article: Rahul S. Warghane and Rajkumar E, Review On Design and
Optimization of Thresher in Crop Cutting Machine, International Journal of
Mechanical Engineering and Technology 8(11), 2017, pp. 1020–1028.
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=11

1. INTRODUCTION
Mechanization in field of agriculture has been carried out promisingly; the due effect of the
same can be seen in day to day life. With the explosion of population and limited resources it
has become important to develop the system which is most efficient. The review of several
countries around the globe has shown that United Nation leads the field of agriculture
mechanization than its counterparts. Due to mechanization major impact has been observed in
demand and supply for farm labour, profitability of farming. It has also brought considerable
amount of changes in the rural landscape including rural communities. As far as foreign
countries are concerned the adoption of mechanized farming is quiet easy with view of
sustainability and adoption. Whereas in India the adoption of technology is quiet painful for

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 Review On Design and Optimization of Thresher in Crop Cutting Machine

the farmers as farm-field in India are very small so as farmers cannot afford these mechanized
machinery .In concern with all these constrains an effort is taken to develop machine for
farmers in India which is compact and affordable. The most important operation in farming is
cutting and harvesting which contribute about 30 % of total cost of production. In harvesting
the most performed post feed operation is threshing for which many manufacturers like
Ningbo Alfa machinery, Shanghai Quianhang machinery, Pempo developed machines. These
machines though well mechanized and bulky are suitable for large farms which has minimum
thresher length of 2 meter span and the costing which would be anywhere around of about
15000 to 21000 USD which is quiet high. To compel this, work is forwarded and efforts are
taken to develop compact crop cutting machine with combined harvester.
In this paper we highlight the study carried on design and optimization of thresher in crop
cutter with a view to design compact and economical machine. Thresher is a device that first
separates the head of a stalk of grain from the straw, and then further separates the kernel
from the rest of the head .To attain the same objective the base model of machine is
formulated. The review includes the parameters related to design optimization, synthesis of
mechanism, analysis and overview about crop strength, cutting blade design and its
performance parameter, design parameter for thresher.

2. DESIGN OPTIMIZATION
In design optimization parameters related to design has been computed with the reference of
basic geometrical constrains. The design optimization will be overlooked with the view of
application of optimization tools like Discrete Optimization, Genetic Algorithms, Constrained
Optimization, and Dynamic Optimization. The computation related with these techniques is
handled by both MATLAB and Python software.

2.1. Wei-Neng Chen et. al.[1]

Proposed new set based discrete optimization technique is proposed based on the concept of
set and possibility theory. In this technique set-based representation scheme is designed to
describe the discrete search, based on this representation scheme many different kind of
combinatorial optimization problem can be solved. For example a velocity is defined as a set
with possibilities, that is , each element in velocity is assigned with possibility. The function
is defined as V1(V i1 , V i2 , V i3 , V i4 , ….) based on positioning of (i) particle X1(X i1 , X i2 ,
X i3 , X i4 , ….) Similarly universal set E is given for N dimension and solution for analysis if
found by equation E =E1 U E2….. , E1=f(PS , f ,Ω) , Ω = constrains.PS –search space , f –
objective function.

2.2. Michael A. Saunders et. al [2]

Performs a study on constrained optimization through SQP. Sequential quadratic
programming (SQP) method is a technique sued for optimizing the problems regarding
constrained optimization. As in present work the design will be subjected to various
constrained regarding geometry, strength, space, weight & cost. Here we consider problems
with general inequality constraints (linear and nonlinear). In SQP an algorithm is designed
that uses a smooth augmented Lagrangian merit function and makes explicit provision for
infeasibility in the original problem. The sequential quadratic programming (SQP) methods is
to solve the nonlinearly constrained problem using a sequence of quadratic programming
(QP) sub-problems. An alternative QP solver is also proposed instate of algorithm. The
optimality of this method gives the feasibility through tolerance band

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 Rahul S. Warghane and Rajkumar E

2.3. Mortain A Kamian et. al [I]

Stated approach for dynamic optimization. A dynamic optimization is applied to an objective
function which is time constrained. The typical objective function can be stated as Minimize

ƪEnd i=1Ƹn(
Start Which may has an inequality constrains like Ai defines the position. N =
No of position parameters, CS =Cross Sectional area, Fi = Moment produces. Such a dynamic
model can be solved by Calcus of Variation, Optimal Control and Static Optimization. The
Calcus of variation uses derivative approach like which is a time bound subjected to position
constrained for ex. Minimize 0ƪt (ử 2) dt .ử = C1 , u = C1 T + Co where C1 and Co are the
constant depend on the initial and final condition .The optimal control uses software iteration
method. The iteration method is applied to mathematical model of given objective function.

3. SYNTHESIS OFMECHANISM
A mechanism synthesis is constructing and framing out the mechanical linkages in such a
constrained manner to get desired motion as work output. Threshing can be achieved by three
methods namely rubbing, impact and stripping. Threshing loosens the grains and separates
from the stalk. The function can be served mostly by two methods, by impact or by crushing.
In impact method an impact is given on crops and the grains are separated. Crushing is one in
which the crop mass passes through a gap between drum and concave. Wearing or rubbing
action takes place that separates the grains from panicle. In each case rupture of the bond
between grains and ears is due to Impact of beaters or spikes over grains and wearing or
rubbing action.
Research has been carried out to improve the performance characteristic of thresher.
Paulsen states that the moisture content of grain is one of the major physical factors for the
design and operation of the threshing machine.

3.1 Huynh et al.[3]

Stated that the seed separation from stalks and passage of seed through the concave gate is a
function of some variables such as feed rate, threshing speed, concave length, cylinder
diameter and concave clearance. These variables affect the threshing losses also seed
separation efficiency

3.2 Kaul et. al [4]

Stated that an optimum speed is desirable to get an optimum performance of a thresher as
excessive speed can cause the grain to crack, and too low a speed can give unthreshed heads.

3.3 Gol and Nada et. al [5]

Concluded that the important factors affecting the efficiency of mechanical pod stripping
elements are operation speed and crop conditions. Percentage of stripping pods increased by
increasing of peripheral drum speed which ranged from (473 rpm) 0.1m/s to (675 rpm) 3 m/s.

3.4 El-Behairy et al et. AL [6].

Stated that the feeding rate perform linear relationship with g drum speed. The feeding rate
depends on the skill of the thresher labour. The volume reduction decreased by increasing
drum speed whereas the grain losses decreased.

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 Review On Design and Optimization of Thresher in Crop Cutting Machine

3.5 Afify et. al [7]

Developed a simple flax thresher to extract the capsules with minimum stalk damage. His
basic design based on three drum shapes (peg-teeth, beaters, and peg-teeth with beaters). The
observations showed that the drum with beaters attains different efficiency associated with it
as threshing efficiency of 96.52 %, separation efficiency of 98.21 %, cleaning efficiency of
95.79 %, stripping efficiency of 99.35 %, threshing capacity of 1.01 t/h, energy, 2.79
kW.h/ton and less criterion cost of 10.29 L.E / ton under the conditions of drum speed of 5.23
m/s and capsules moisture content of 14.20 %.

3.6 WR Nave et. al [8]

Observed that the threshing efficiency increased with increasing drum speed and decreasing
feed rate. The threshing efficiency attains the maximum value as 99.76 % at drum speed of
21.25 m/s (1400 rpm), and feed rate of 15 kg/min. The grain damage was 0.90 % of visible
grains under operating condition.

3.7 El-Nono and Mohammed et. al [9]

performed the study on machine power requirement , drum speed , moisture content and grain
damage .The research state that machine was directly proportional to the drum speed. Also the
moisture content and grain damage highly affect the power requirement. The experimentation
found that the swinging hammer, spike tooth and rasp bas cylinders affect threshing
effectiveness and damage of wheat. It has also been seen that the cylinder speed and concave
clearance were found to be important variable in unthreshed grain and damage model.
Variation in cylinder speed and concave clearance varies the volume of unthreshed grain .The
increase in cylinder speed and decrease in clearance increases the power requirement. The
overall result of experimentation shows that the swing arm type is less effective than the rasp
type.

3.8 Mandouh et. al [10]

Stated the relation between different threshing parameter like cylinder speed, the concave
clearance, feed rate of crops, the number of rows of concave teeth used with spike tooth
cylinder, and the type of crop and Threshing effectiveness

3.9 Simonyan and Oni et. al [11]

Reported that there is an increase in threshing efficiency and extractor efficiency with
decrease in moisture content. Threshing effectiveness is a function of cylinder speed and
perform linear relationship between both.

3.10 Badawy et. al [12]

Reported that the highest threshing efficiency was 97.17 % at the optimum performance of
flax deseeding machine. The observations recorded that for drum speed 9.28 to 15.33 m/s the
capacity increased from 1800 to 2400 kg/h.

3.11 El-Ashry et.al.[13]

indicated that for one Mg of flax, the threshing cost found as d as 44.44 L.E at complete
mechanized system , due to increase in the stalk losses and damage, while the cost of
conventional system was 37.76energy requirement were 3.19, 3.4, and 1.6 kW.h/Mg for
complete, partial mechanized and conventional systems, respectively.

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 Rahul S. Warghane and Rajkumar E

3.12 Zakaria et. al [14]

Developed the threshing drum in a local stationary thresher to suit separation of flax capsules.
The machine was tested under feed rates of 8.57, 12.86, 17.14 and 21.43 kg/min, and four
drum speeds of 24.25, 25.81, 27.33, and 28.85 m/s. The results showed that the optimum
performance was at drum speed of 28.85m/s, feed rate of 8.57 kg/min, drum fingers of 12 and
separation time of 15 seconds where the threshing efficiency was 96.92 %.

3.13 Zaky et. al [15]

Recommended that the optimum conditions to reduce the seed damage and total losses of seed
with acceptable level of cleaning efficiency were the drum speed ranged from 3.3 to 4.4 m/s,
clearance ranged from 2.5 – 3 mm and air velocity of 2 m/s to consumed energy of 25.12
kW.h/ton and criterion cost of 752 L.E/ton. Heretofore, there are no papers published on the
design or development of a machine for threshing Soya bean seed capsules. With the
availability of reports on the properties of other similar crops and threshing, the objective of
this study concerned in development of appropriate threshing machine suits Soya-bean black
seed which will reduce the drudgery associated with the traditional methods of threshing
Soya-bean seed capsules with high stripping, threshing and cleaning efficiencies in addition to
low required energy and cost.

4. ANALYSIS AND OVERVIEW ABOUT CROP STRENGTH

In the proposed work an efforts has been taken to design and optimize thrasher. The thrasher
has to perform the cutting and thrashing action on the crop which if fed through it. The
thresher design is thus completely affected by the resistance imparted by crop volume. The
volume implies stem leaves and capsule. With a view to design the research is overlooked for
physical and mechanical properties of crop. In the research discussed above it have already
states that the moisture content highly affects the strength and threshing characteristic. The
findings for the same on the basis of review are discussed as below.

4.1 Rafique Polac et. al [16]

Performed experimentation on soya bean crop in Turky.The moisture content measurement
has been made and he found the average moisture content as 6.67 and max limit as 15.3 %
.So, he states the physical properties at the given percentage. The sampling has been done on
100 samples properly cleaned and dried for test. The average value requited for optimum
design whereas the maximum value required for the maximum strength. Average length ,
width , thickness , unit mass , geometric mean dia , spericity , porosity , true and bulk density
were 7.1 mm 5.34 mm , 4.30 mm , 121.76 gm , 5.62 mm , 5.75 mm , 75.0 , 51.0 ,1062.6 and
108.8 kg m3 respectively . Corresponding value at 15.3 % moisture content were 9.57 mm ,
6.75 mm 5.75 mm , 75.0 , 51.0 , 10626 and 804 kg m3

4.2 Piotr Kuźniar1 et. al [17]

States the influence of the chemical composition and moisture content in seeds from selected
soybean cultivars on their mechanical properties. The mechanical properties have been found
out by applying the quasistatic load on the crop sample with the help of universal testing
machine. The the test result shown that seed ruptured significantly for the small amount of
rupture force (105.6 N) was applied and were most prone to deformation (29.2%). The
significantly highest modulus of elasticity (1721 MPa) was observed in the cv. SP-16 seed.
An increase in the moisture content in seeds caused a significant decrease in the rupture force
and modulus and an increase in deformation and energy. Soybean seeds were the widest (7.03

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 Review On Design and Optimization of Thresher in Crop Cutting Machine

mm), the thickest (6.15 mm), the roundest (92.53%) and the heaviest (209 mg).The lowest
energy required for rupture is 71.5 mJ.

4.3 H. Kibar et. al [18]

Performed the physical and mechanical properties of soybean. In this moisture range, grain
length, width, thickness, arithmetic average diameter and geometric average diameter
increased from 7.24 to 8.19, 6.79-7.12, 5.78-6.23, 6.60-7.18, 6.57-7.14 mm, respectively. The
volume of grain and area of grain surface increased linearly from 130.97 to 160.32 and from
125.46 to 144.39 mm2, respectively. The spericity, bulk density, true density and porosity
decreased linearly from 0.91 to 0.87, 766.12-719.00, 983.33-905.67 kg m-3 and 22.58 to
20.61%, respectively. The angle of internal friction increased linearly from 27.37 to 31.81
with the increase of moisture content. The static coefficient of friction increased from 0.385 to
0.571, 0.304-0.441 and 0.164-0.286 for concrete, wood and galvanized steel surfaces,
respectively.

4.4 Liang li et. al [19]

Performed the study for stalk shear strength. The work has been performed to provide design
parameters for harvesting machinery cutter, and exploring the relationship between shear
strength and morphological traits. This strength can be utilized to adjust the shear strength in
selecting crop variety process. About seven morphological traits (such as plant height, ear
length, ear weight, moisture content and so on) were measured in the crop mature period. The
maximum shear force during shearing process, through static test equipment, at the second
internode of the basal stalk, was recorded. Based on the experimentation the findings for
different mechanical properties are plant height 81.9 cm , Internodes distance 7.9 cm ,
Internode weight 5.68 gm , cross sectional area 82.77 mm2 , Shear strength 21.7 N , Shear
stress 2.62 MPa.

5. CUTTING BLADE DESIGN AND ITS PERFORMANCE

PARAMETER
In the present work on the basis of concept diagram the cutting action implies at the crop
cutting where the strand of crop is cut by means of shear principle. The thresher crushes the
crop volume and extracts the seed from capsule. Also, while design of thresher for axial flow
thresher involutes blade is required to produce draft. The cutting blade has to be designed
with a view to impart crushing action on the seed instate of shearing. On the basis of review
of crop strength it has seen that the soya bean crop has very high modulus of elasticity of
about 1721 MPa meanwhile it has very less shear strength of 2.62 MPa. Considering all these
constrain the blade has to be designed to impart crushing force on capsule for seed extraction.
The review for the same discussed as under.

5.1 Sunil K. Mathanker et. al [20]

Carried out an experimentation and study on optimization and design of cutting blade. He
evaluated the effect on cutting energy by cutting speed and blade oblique angle. For an
experimentation an impact type cutting mechanism was used . The mechanism determines the
cutting energy cost of individual stems. The observation recorded stated that the specific
cutting energy increases with cutting speed. The recorded result shows that lowest average
specific energy was 0.26 J mm1 for a 60 oblique cut at an average cutting speed of 7.9 m/s.
The highest average specific cutting energy was 1.24 J mm-1 for a straight cut at an average
cutting speed of 16.4 m/s. The specific cutting energy stated a close correlation with stem
diameter and stem cross-sectional area. The observation found at a 30 oblique angle at 11.3

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 Rahul S. Warghane and Rajkumar E

m/ s average cutting speed as the cutting energy varied from 4.5 to 15 J as the stem diameter
varied from 11 to 17 mm. On the basic of review we found that optimization of cutting speed
and blade oblique angle can result in significant savings in cutting energy, also improving the
quality of cut.

5.2 Y. D. Yiljep et. al [21]

Developed test-rig for measuring cutting energy requirement and cutting efficiency on
sorghum stalk based on the principle of oscillating arm type pendulum like Jommy and
Quench test setup for impact strength measurement. In this method the author fixed the
sorghum stalk in stalk holder to initiate a free-impact on standing stalk. A cutting blade with
bevel angle of 30% at its edges, was attached to the lower end of the arm .This blade cuts the
stalk at 90o to the stalk axis with knife velocities up to 8.5m/s. While cutting above ground
level the sorghum stalk base (20 mm) and stalk height (120mm) experiment was conducted.
The observations recorded as there was high correlation of p≤0.1 for the knife velocity,
cutting energy requirement and cutting efficiency. A negative linear correlation was observed
between knife weight and cutting energy requirement and positive linear correlation between
stalk moisture content and cutting efficiency. The minimum cutting energy requirements for
20 and 120 mm were 7.87 and 12.55 Nm respectively, at corresponding knife velocities of
2.91 and 3.54 m/s. 98 and 97% at 5.2 and 7.3m/s knife velocities were the maximum cutting
efficiencies that were observed.

5.3 Reza Tabatabae Koloor et.al [22]

Performed the study on cutting of soya bean crop with a view to aid in engineering design and
modification of cutting mechanisms in soybean harvesters .It also helps to investigate the
effects of blade parameters on cutting energy. To perform this investigation an impact shear
test apparatus was designed and constructed to measure the energy required for cutting
soybean plant stems. Observations on Iranian Sahar type, in different blade velocities (2.5,
3.75, 4.5 and 5.45 m s(-1)) to determine the optimum values of blade bevel angles (18, 23, 28,
33 and 38 degrees), oblique angles (10, 20, 30, 40 and 50 degrees) and tilt angles (15, 25, 35,
45 and 55 degrees). It is observed that the Specific Cutting Energy (SCE) optimum was
obtained at 23 degrees blade level angle , 30 degrees oblique angle and tilt angle of 25
degrees and blade velocity of 3.75 m s(-1).

6. DESIGN PARAMETER FOR THRESHER.

The basic frame model formulated for design and optimization of thresher facilitate the
tangential flow type of thresher. The concept formulation for tangential thresher has been
performed. The tangential thresher permits the crop volume from its outer periphery and the
drum blades perform threshing action on the crop volume. The cage and blade assembly is
designed such that it produces an induced draught on thresh volume. The crop residues are
light in weight and flew away by the draught whereas the seed get settle through bottom of
cage. The design parameter thus defines as bulk density analysis, design for cylinder drum
and speed calculation for draught generation. With the same view the research has been
performed and the findings are discussed as

6.1 Ali Mirzazadeh et. al[23]

It has performed analysis on optimizing the design parameters like threshing clearance ratio ,
feed rate , cylinder velocity and bulk density. He plotted down the characteristic graphs for
the performance parameters. For source model formulation of axial thresher the basic
mathematical function given as Sn(x) = 1-exp(-ɺ x) and rs(x) = exp(-ɺ x) in which rs refers to

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 Review On Design and Optimization of Thresher in Crop Cutting Machine

remaining grain to be separated , ɺ is constant coefficient separation .Similarly different

characteristic equation has been formulated for different parameter .Through the paper we got
an idea for the functional relationship of different design parameter.

6.2 Victor Ifeanyichukwu et. al [24]

Developed a mathematical model to evaluate the output capacity for threshing process. For
the base he uses dimensional analysis method using the logic of Buckingham’s Pi Theorem.
Parameters for dimensional analysis considered as Output capacity CT MT–1, Federate Fr
MT–1 Grain - straw ratio Z −Separation efficiency.Throgh the study different model
formulation has been done with the aid of coefficients to validate the expression. The results
were validated through statically data provided for millet thresher. The results found
correctness about 5 % tolerances.

7. CONCLUSION
In the present work the research has been carried out to optimize and design the thresher for
cutting soybean crop. The blasé assembly best suited for the function is reciprocating blade
type. Experiments carried on soya-bean crop strength give s the mechanical properties like
density shear strength coefficient of friction .The synthesis of mechanism gives the basic idea
for frame selection and development of model to serve the purpose..Design optimization
techniques have been overlooked which shows that the derivative approach and matrix
iteration with mathematical modeling gives the best result for design optimization.

ACKNOWLEDGMENT
The review is performed with the reference of research papers available through various
research publication website. We are very thankful for all the researchers to share their work
with us.

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