Design & Fabrication of

Sugarcane Cutting
Machine
 ABSTRACT

India is an agricultural country, In which 70% people are farmers. As, the population of India is
growing, the demand of food is also increasing. Therefore, we should try to bring more land under
cultivation.
Under these circumstances, we are in need of fast cutting process instead of
traditional cutting methods. In past, agri-related activities were taken care by means of manual force.
But now a days in most parts of our country there is scarity of labours; hence labours are not available
when required. So the labour cost is increased as for cutting of sugarcanes only skilled labours are
required.
To minimize the labour cost and to get work done in minimum, time at cheap cost
we have designed “SUGARCANE CUTTER’. It is simple in construction. It does not need skilled
labour.
INTRODUCTION
In primitive India, agri-related activities were taken care of by manual means. But in
most of the parts of our country, there is a scarcity of labours and hence labours are not available when
required. This gives an opportunity to develop some new method. So, mechanization of agriculture
equipment becomes necessary.
INDIA is the country of farmers and near about 70% of it's Population depends on
agriculture. The History of Indian farmers tells us today how they have achieved the comfortable
position. He acquired the skill of raising crops which provided food whenever he found good fertile
land, he settled down and took to agriculture and also followed other pursuits of its which made him
richer and more comfortable.
As the population Increased food was not sufficient and surplus population of more on
the other areas not so productive. As a result of demand of food is increased, man is trying to bring and
more land under cultivation, under these circumstances we are in need of fast cutting procedure instead
of manual crop cutting.
So we have to adopt mechanical means for the purpose of cutting crops. This alternative
is not only fast but also very cheaper than the conventional manual crop, cutting.
Manual Sugarcane Cutting By Sickle
Generally manual sugar cane cutting involves slicing and tearing action that results in
plant structure failure due to compression, tension or shear. This manual sugar cane cutting practice is
followed by majority of farmers because of socio- economical and agro-technological reasons. Different
types of sickles are used in different part of country.

Principle of Sickle
Designs of sickles are based on principles of two types of cutting friction and shear. It is
assume that the cutting action is taken place due to friction when the knife-edge of the cutter slips
around the stalk.
The serrated sickle combines the slicing and sawing action. The Serrated edge used in
cutting devices restricts the sliding action of the plant on the blade for adequate action of the plant on
the blade for adequate cutting. It has been Reported that sickle with serrated edge do not required the
repeated sharpening needed by smooth edge sickles.
 Single Impact Cutting
Cutting energy as affected by various engine parameters. Cutting energy is defined as a
energy require to cut the plant stem, a process of cutting of stem is done through shearing action.
Liljeghl (1961) while working with element, of shearing energy suggested
some variables, which affect the energy, required.
The variables are :-
1] Plant Variables
a] Moisture Content,
b] Maturity of crop
c] Variety of crop.
2] Design variables
a] Thickness of cutter.
b] Speed of cutter
c] Feed roll force.

Cutter Blade
A] Blade Sharpness :-
The sharpness of blade is an important parameter in cutting process. It was observed that
sharpness is affected power requirements. A blade having Leading edge thickness less than 0.127 -mm
required 35% less energy.

B] Blade Velocity :-
Blade velocity is the another important parameter in cutting process. This velocity
depends upon diameter of blade and no. of RPM. As diameter & RPM are less the time and force
required for cutting will be more and vice- versa and hence optimum value of diameter & RPM must be
taken into consideration.

π DN
V=
60
V = KDN
π
Where K = 60

V ¿ DN
 Prasad & Gupta (1975) observed that the cutting energy per unity area and cutting stress
were minimum at a velocity between 2.5 to 3.0 m/sec. And optimum value of velocity was 2.65m/sec.

C] Dia. of Stem :-
Cutting forces are changed according to the dia. of stem. According to the category of
sugarcane. The strength & diameter of stem varies and thus the Cutting force also changes.
Diameter of stem = 2.5 cm to 3.0 cm.

D] Determination of Shear Force :-

In contrast to compressive and tensile stress, which cut normal to plane shear stresses, act
parallel to the shearing plane. If tensile and compressive stresses are act only in one direction the shear
stresses but oppose force acting through the centroid of sections of material are spaced theoretically
infinitesimal distance apart.
In practical situation, however the case of a rivet in shear is approximation of this
condition. If the parallel and opposed shearing forces do not lie in a plane containing longitudinal axis of
the body a couple is set up which produces twisting action termed torsion.
In agricultural material sometime the term shearing has been used for process which is
actually a cutting process and not true shearing.

Drawbacks in Conventional Sugarcane Cutting Process :-

1] Time require for completing process is more .
2] The farmer cannot get the proper no. of workers at proper time.
3] Loss due to idleness of labour is more .
4] Wages problem arises.
Due to these drawbacks in conventional cutting many numbers of industries, economists
are doing research to solve this problem. Till now crore of rupees have been spend but new problem
arises, as pieces of land in India are small. The research made by them is not suitable for small
agriculturists. Hence they are trying to fabricate that will suit small agriculturists of India.
OBJECTIVE

After going through the literature, the gap that was found was that the sugarcane harvesters developed
are not economical as they are able to cut the grains but there is a problem of collecting the grains. The
commercial sugarcane harvesters are available in large sizes and that’s too costly so to overcome these
difficulties, the following objectives are listed down:
1. To create a low-cost sugarcane shearing machine, that can cut the grains with minimal cost.
2. To prepare a machine that is more productive and possess straight forward instrument for cutting
the sugarcane at a very fast rate.
3. To create the cultivated sugarcane gathering attachment which is simple to work.
4. To produce an economical machine for small scale farmers.

FUTURE SCOPE
In present machine there are still modifications to get better results, better efficiency and
easy operation.
Hence we suggest following some modifications.
1) Gear Box :-
In place of direct pulley transmission. If gearbox is used then different types of speed
range are available on the cutter. Gearbox prevents the entry of dirt and dust particles in the gear.
Also gearbox absorbs the damping and makes the operation noiseless and hence the life
of gear increases.
2) Automotive :-
By giving the same engine power to the wheels by the use of suitable arrangement the
machine can made automotive. Due to this operator does not require to push the machine and hence he
can operate machine easily.
3) Clutch :-
Clutch is used to connect the engine shaft to gear shaft. Thus while starting the machine
clutch is disengaged by operating clutch lever this reduces the load on engine at the time of starting.
Also it is very essential to stop the machine at required position. Hence by disengaging the clutch
machine and cutter stops at required position without stopping the engine. If this is not done at required
time, these create problems and there are chances of accident, so clutch is very essential in machine.
4) Steering Arrangement :-
 By using front wheel castor and giving some steering to it. It is very easy for operator to
turn the machine without lifting, the machine thus it can save the energy and time of operation.
5) Gripping and collecting Unit :-
While harvesting the major problem arises is that falling of sugarcane on and in front of
machine. This creates problem in operation of machine. So thee must be auxiliary gripping and
collecting unit and that is proposed.

METHODOLOGY

To completely provide a design of the machine, the following stages of the design were incorporated to
have a proper design methodology

1. Design Conceptualization: Based on needs of the farmers and the market survey conducted. Different
iterations of the design of machine were prepared.
2. Calculation and outline validation: planning stage is imperative stage as quality, weariness, factor of
safety, every single specialized point was taken while doing the computations and configuration. •
 Prototype making and testing:
3. After finishing the calculations, a three-dimensional assembly was made virtually on the software
within the genuine conditions which gave a perspective of the real world and its quality that allows
doing testing of any sort conceivable.
4. Testing: After assembling the model, testing was done to check the feasibility of the model. This is
also done using the virtual simulations.
 LITERATURE REVIEW
1. SUGAR-CANE HARVESTING MACHINE DESIGN “IN THE FIELD”
LIDIANE REGINA NARIMOTO MSCA, ROBIN BURGESS-LIMERICK
PHDB
Proceedings 19th Triennial Congress of the IEA, Melbourne 9-14 August 2015 1
Sugar-cane harvesting machine design “in the field” Lidiane Regina Narimoto MSca, Robin
Burgess-Limerick PhDb a Department of Production Engineering, Federal University of São
Carlos, São Carlos, São Paulo, BRAZIL; bSustainable Minerals Institute, The University of
Queensland, Brisbane, Queensland, AUSTRALIA.
Mechanical sugar cane harvesting machines were first developed by farmers in Australia. In
early 1970s the Australian concept of harvester served as inspiration for the production of the
first successful machines in Brazil. This research explored the design of these machines in Brazil
and in Australia. Task analysis of machine operation, questionnaires and interviews with
harvesting teams were undertaken at five sites considering both countries. It was observed that
maintenance staffs made several modifications to the machines to improve reliability, operation,
productivity, maintenance and safety. It is believed design in use should be taken into account
during the design process.
Practitioner Summary: the study explores the design of sugar cane harvesting machines and
identifies the design modifications undertaken by field maintenance staff to improve severa
issues of the equipment. It is discussed that designers and workers should participate in the
harvesters’ design, according to their diversity and their specificities.
Brazil is the largest sugar cane producer in world and its last season (2013/2014) surpassed 650
million of tonnes (UNICA, 2014). Over the last decade, the country has experienced a process of
harvesting mechanization due to environmental, social and economic demands. Nowadays,
around 85% of the whole Brazilian crop is mechanically harvested (CTC, 2012).
The first successful sugar cane harvester was built in Brazil in 1973, adapted from the Australian
concept (RIPOLI, VILLANOVA, 1992). Australia led the sugar world in the adoption of labour
and cost-saving mechanisation. According to Kerr and Blyth (1993), today’s sophisticated cane
harvesting systems are the evolutionary product of more than 100 years of improvisation and
adaptation. The pursuit for a successful machine in Australia began in 1890 when the first design
was patented and since then, many growers were dedicated to the task of creating a reliable,
practical machine suitable for the industry’s needs. Currently, two
 multi-national equipment manufacturers are the leaders in production of these machines.
Although the machine design is “corporatized” by large manufacturers, as pointed by Béguin
(2003), the design of an instrument is far from being finished when the final technical
specifications leave the research and design office. The inventiveness and creativity shown by
users when faced with technique is a necessary condition for the efficiency of their activity.
When users appropriate of artefacts, there is a specific process of construction and reconstruction
of uses and devices: in other words, design continues in usage (RABARDEL, BÉGUIN, 2005).
The processes by which the users continue design in usage are called instrumental genesis and
consist of instrumentation and instrumentalization (RABARDEL, BÉGUIN, 2005). According to
Béguin (2007), instrumentation involves form of actions, i.e., the operator develops new
techniques stemming from those he/she already disposes of. Instrumentalization, on the other
hand, is related to the artefact’s properties, so the operator adapts, modifies, transforms the
devices to mould them to his/her own constructions. As highlighted by Rabardel and Waern
(2003), the existence of instrumental genesis is not an effect of a deficient design, but rather an
expression of the concept embodied by the artefact that is in all ways instantiated by the user.
Design, thus appears as an activity distributed between designers (design for use) and users
(design in use): designers elaborate a proposition in form of artefacts and users may take
advantage of these propositions (totally, partially or not at all) in order to develop instruments
that fulfil their needs, considering the organisation and the situations.

2. A REVIEW ON SUGARCANE HARVESTING AND THRESHER

MACHINERIES
This paper is focoused on development of sugarcane harvesting machines and threshing
mechanism develop inside harvester. Nowadays there are need of fast production of agricultural
products. 75% Indian economy is based on agriculture. So development of agriculture field is
considered as development of India. But nowadays because of industrialization shortage of labor
found in agriculture field. . Day by day labor demands about their salary are also increased. This
review paper is a small work towards analyzing sugarcane harvester machine aspects for
economical harvesting which will help to minimize the working fatigue and to reduce labor cost.
Today’s world there is a heavy demand for sugar and its byproducts. The major states growing
sugarcane are Maharashtra, Uttar Pradesh and Karnataka. Now India is the leading producer of
sugarcane in the world.
This project aims to reduce labor as well as farmer’s effort and to increase the output of
agricultural products. If compared to other harvesting machines, this machine can cut the two
side from the lower, and upper portion of the sugarcane, and threshing mechanism removes all
the leaves, and pass sugarcane to the tank. Higher cost machine cant to purchase by common or
middle class person, hence cost reduction is our main focused.

Sugarcane is the major economic crops in India. It is used as a raw material in sugar
manufacturing. Recently India is the second-biggest sugar producer country after Brazil. The
Indian agriculture depends heavily on human labor which results in low productivity per hector
of per labor, so it wastes a lot of time on working process. Indian agriculture has facing
challenges like shortage of agricultural labor, not only in peak working as but also in normal
time.
This is mainly for increased nonfarm job opportunities having higher wage, migration of labor
force to cities and low status of agricultural labors in the society. Human labor shortage tends to
be a serious problem in rapid agricultural industrial development. Sugarcane leaf-removing tools
could help speed up sugarcane harvest and reduce contamination.
Harvesting is a process of cutting and gathering of mature crop from the field. Harvester is a
machine is used for harvesting. Different types of harvesting machines are available in the
market namely paddy harvester, Tea harvester, Potato harvester, Wheat harvester and sugarcane
harvester, as mentioned above all are available in small scale except sugarcane harvesting
 machine. Sugarcane harvesting is an agricultural machinery use to harvest and process
sugarcane.

3. REVIEW PAPER ON VARIOUS ASPECTS OF PORTABLE SUGARCANE

HARVESTER Mayur Vasant Raole1 Prashant N. Awachat
This paper discusses the overview of the sugarcane harvesting, current processes used for
sugarcane harvesting, need of the portable sugarcane harvester, various designs of sugarcane
harvesting machines, problems regarding the current design of portable sugarcane harvester and
possible solutions are also suggested to make the portable sugarcane harvester more efficient,
economical and reliable for small scale sugarcane producers.
As the name explains itself this machine is used sugarcane harvesting, this machine is designed
for the small-scale sugarcane producers. Sugar can be assumed as important as salt which is
produced form the sugarcane. India is the one of the largest producers of sugar. India was the
second largest producer. Sugarcane harvesting is one of the most time consuming as well as
laborious job. Sugarcane is tall grass with thick stalk and harvested manually by cane cutter and
transported to nearly mill. Portable sugarcane harvester is the better option for the small-scale
sugarcane producers. As we all know agriculture product demand is increasing day by day at the
same time labor wedges are also increasing. Today’s world demanding of production of
agriculture products in faster rate. This project aims to modify the current design of the portable
sugarcane harvester to improve its efficiency and reliability.

4. DESIGN OF SUGARCANE HARVESTING MACHINE

Agriculture is the backbone of India. In India almost all farmers facing problems of labour
shortage. In today‟s world we required faster productivity in less time. About 65-70 % of Indian
population depends upon agriculture. So for fulfilling the future demands there is need of
advancement in techniques and equipment‟s of farming at economic cost because in India every
farmer can‟t afford tractor and other high cost machine equipment for the harvesting. Day by
day labour wages are increasing and in the same way demand of agriculture products are also
increasing and today‟s world need faster rate of production of agriculture products. This
machine does the work with less efforts and in less time so it reduces cost of labour required for
seed sowing and fertiliser placement. The cutting force of sugarcane is varied 29.14 to 106.57 N.
 As India‟s population is growing so the demand for food will definitely increase for that better
techniques of farming will require to increase production. In India agriculture has facing serious
challenges like scarcity of agricultural labour, not only in peak working seasons but also in
normal time. This is mainly for increased non- farm job opportunities having higher wage,
migration of labour force to cities and low status of agricultural labours in the society. Sugarcane
is the world‟s largest crop 2010 Food Agricultural Organization (FAO) estimates it was
cultivated on about 23.8 million hectares in more than 90 countries, with a worldwide harvest of
1.69 billion tons.
Harvesting is a process of cutting and gathering of mature crop from the field. Harvester is a
machine used for harvesting. Different types of harvesting machines are available in the market
namely paddy harvester, Tea harvester, Potato harvester, Wheat harvester and sugarcane
harvester as mentioned above all are available in small scale except sugarcane harvesting
machine. Hand knives, cutting blade or hand axes are used for manual harvesting. It requires
skilled labours as improper harvest of cane leads to loss of cane and sugar yield, poor juice
quality and problems in milling due to extraneous matter. Labours can't cut sugarcane properly at
ground level.

5. DEVELOPMENT OF THE SUGARCANE HARVESTER USING A SMALL

ENGINE IN NORTHEAST THAILAND T. MOONTREE, S. RITTIDECH*
AND B. BUBPHACHOT
This research presents the developing sugarcane harvester using small engine in order to focus
on its appropriateness in sugarcane farming for farmers who are encountering problems of labor
shortage and sugar factories lacking sugar cane for producing sugar. It is operated by 180 hp
(134.28 kW) at 2500 rpm. Sugarcane was harvested at 12 months after planting with an average-
stalk length of 1.8 m, and average-stalk diameter of 0.0254 m; each clump consisted of 8 to 12
stalks, the distance of each sugarcane row was 1.20 m. The sugarcane harvester using small
engine can perform at an average speed of 1109.73 m2/h with fuel consumption of 20.03 l/h and
at a mobile speed of 0.25 km/h. The percentage of sugarcane-cut stalks is 100% since this engine
is installed with double blades with a speed of 1,090.5 rpm; a speed of leaf-cutting blades is at
669 rpm with the break even point of 122,572.8 kg/year and the payback period of 2 years.
Development of sugarcane harvester using small engine in order to be suitable for farmers in
sugarcane farming in northeast Thailand revealed that this engine can perform its cutting
efficiency at an average speed of 1109.73 m2/h with fuel consumption of 20.03 l/h and at a
mobile speed of 0.25 km/h. The percentage of sugarcane-cut stalks is 100%; since it is installed
with double blades, all stalks are smoothly cut. A rotation speed of a stalk-cutting blade is at
1,090.5 rpm, a rotation speed of a leaf-cutting blade is at 669 rpm. The economic evaluation
represents the break even point of using harvester of 122,572.8 kg/y and payback period of 2
years.
 IMPROVED SUGARCANE CUTTING MACHINE
In previous article we have discussed the limitation of conventional sugar cane cutting
operations.
Considering this problem we have made the sugar cane cutting machine with two rotary
cutters run by tractor engine. This machine performs the same operation as that of manual cutting by
sawing the labour work.
In this machine, the engine power is transmitted to pulley, which is directly mounted on
the spindle. This speed is transmitted to the cutter through spindle shafts. By considering the friction
loss in the flexible shaft, the speed at both cutters is near about 1000rpm. (Considering losses in flexible
shaft is 5-10%). These losses due to the friction between can be reduced by the use of proper lubricants.
On both sides of machine the cutters which are rotating are mounted. Both cutters rotate
in same direction. Thus the rotations of both cutters are in such direction so that cutting operation the
tendency of cutters is to throw the sugar cane outward. So after cutting it will not fall on the frame of the
machine.

Principle :-
The working principle of sugar cane cutting is as follows;
It works on the shear cutting principle. When the blade having very small thickness
imparts on a cylindrical surface, the surface gets cut in a plane. The equation can be written as follows:
F = A x fs
Where, F = Force require to cut the crop in Newton
A = area of shear
fs = Shear stress.
As sugarcane are having their stems of circular cross section.
Therefore, F = π /4 x d2 x fs
Where d = diameter of sugarcane stem.
 DETAILS OF SUGARCANE CUTTING
Sugarcane Considerations :-
The soil and water are two variables, which either have to be suitably adjusted for the
plant to grow. The plant showed be so bred and adjusted that it will adjust to given soil and water
conditions, sugar cane takes one year to matured on the basis of life of crop. It is known as a seasonal,
annual and perennial.
India is a country of small farmers whose holdings are not only small but fragmented.
They carry-out many farm operation with hand tools.

COMPONENT DESCRIPTION

Parts Description of Sugarcane Cutting Machine :-

Frame :-

Base frame design:

WE design a basic frame for a prototype by mild steel channel (L beam),

L Channel- MS Angles are L-shaped structural steel represented by dimension of sides & thickness. For
e.g. 25x25x3 means, both the sides of angles are 25 mm & thickness is of 3 mm. There are various sizes
of angles which are as follows :-( there are also equal & unequal angles). Equal angles: - They are
angles having both the sides of equal dimensions. For e.g. refer below given diagram, in which both the
sides are of dimensions “a”.

Fig. L-angle bar dimensions

By standard available sizes we select the 25 mm so because that will be easily available and have
appropriate size for frame.

SIZES WITH SECTION WEIGHT OF EQUAL ANGLES

Size Weight in Kgs. Gauge Thickness

in mm Per Feet Per Mtr.
20x20x3 0.274 0.899 3mm
25x25x3 0.335 1.099 3mm
25x25x5 0.548 1.798 3mm
31x31x3 0.390 1.280 3mm

Motor
Type – 12 volt geared DC motor:
A DC motor is any of a class of electrical machines that converts direct current electrical power into
mechanical power. The most common types rely on the forces produced by magnetic fields. Nearly all
types of DC motors have some internal mechanism, either electromechanical or electronic, to
periodically change the direction of current flow in part of the motor. Most types produce rotary motion;
a linear motor directly produces force and motion in a straight line.

DC motors were the first type widely used, since they could be powered from existing direct-current
lighting power distribution systems. A DC motor's speed can be controlled over a wide range, using
either a variable supply voltage or by changing the strength of current in its field windings. Small DC
motors are used in tools, toys, and appliances. The universal motor can operate on direct current but is a
lightweight motor used for portable power tools and appliances. Larger DC motors are used in
propulsion of electric vehicles, elevator and hoists, or in drives for steel rolling mills. The advent of
power electronics has made replacement of DC motors with AC motors possible in many applications.
Gear motors are electric motors that utilize a type of gear system on the output of the motor. This
gearing arrangement is called a gear reducer or gearbox. The combination of an electric motor and
gearbox reduces design complexity and lowers cost, particularly for motors built for high torque and low
speed applications. In addition, gearboxes can be used as a means to reorient the output shaft in a
different direction.
 Fig. 12 volt, 100 rpm geared DC motor

Performance Specifications:
There are a number of performance specifications to consider when selecting a gear motor.
1. Gear ratio,
Gearbox ratio, or reduction ratio is the ratio of the velocity of the input gear to the velocity of the output
gear in a gearbox. A ratio greater than one indicates speed reduction, while a ratio less than one
indicates speed increase. This ratio is directly proportional to the correlation between the numbers of
teeth of different gears in the system. If an output (driven) gear has 20 teeth and an input (drive) gear
has 10 teeth, the gear ratio would be 2:1. In compound gearing configurations, the overall ratio is the
product of the ratios of each connection, as exemplified in the image below.
2. Torque
Torque is the angular force generated by the motor to handle a required load, expressed in force distance
units such as foot-pounds (ft-lb) or newton meters (N-m). Starting torque defines the torque the motor
produces at startup. Continuous torque defines the torque the motor produces at constant running
conditions. Output torque in a gear motor is largely dependent on the gear ratio used. Larger torque can
be achieved using a higher gear ratio, which also reduces shaft speed.
 3. Speed
Speed (RPM) is the rotational speed of the shaft generated by the motor, expressed in rpm (rotations per
minute). The shaft speed in a gear motor is proportional to the gear ratio. The output speed can be found
by dividing the input speed by the gear ratio. Gear ratios above one will reduce speed, while those below
one will increase speed.

4. Efficiency
Gearbox efficiency is the percentage of power or torque that is transferred through a gearbox.
Manufacturers typically specify the gearbox efficiency as part of the gear motor specifications list to
indicate overall gearbox performance. This efficiency factor takes into account losses that occur due to
friction and slippage inside the gearbox.
5. Backlash
Backlash is the angle that the output shaft of a gearbox can rotate without the input shaft moving, or the
gap between the teeth of two adjacent gears. For applications without load reversals or reverse-
operation, this factor is insignificant. However, in precision applications where load reversals occur
(such as robotics, automation, CNC machines, etc.), backlash is crucial to consider for accuracy and
positioning.
Selected motor specifications:
The GML42x35-25-Z1 gear motors are equipped with EMC filter. The gearbox has ratios of 62:1. In the
technical interactive datasheet is available the gear motor drawing and it’s possible to choose the shaft
and the EMC filter type. To define the characteristic curve with the preferred performances it’s
sufficient to write power voltage and no-load speed within the indicated, allowed ranges or, more
simply, is available the pre-defined characteristic curve. Every selected option is saved automatically in
the below enquiry form, in which it’s possible to load files. In the chart “Electrical Data” are indicated
the performances values for the most commonly used voltages, 12V and 24V.
FLEMING’S LEFT HAND RULE:
Keep the force finger, middle finger and thumb of the left hand mutually perpendicular to one another.
If the fore finger indicates the direction of magnetic field and middle finger indicates direction of current
in the conductor, then the thumb indicates the direction of the motion of conductor.
PRINCIPLE OF OPERATION OF DC MOTOR:
Figure I show a uniform magnetic field in which a straight conductor carrying no current is
placed. The conductor is perpendicular to the direction of the magnetic field.
 In figure II the conductor is shown as carrying a current away from the viewer, but the field due
to the N and S poles has been removed. There is no movement of the conductor during the above two
conditions. In figure III the current carrying conductor is placed in the magnetic field. The field due to
the current in the conductor supports the main field above the conductor, but opposes the main field
below the conductor.
The result is to increase the flux density in to the region directly above the conductor and to
reduce the flux density in the region directly below the conductor. It is found that a force acts on the
conductor, trying to push the conductor downwards as shown by the arrow. If the current in the
conductor is reversed, the strengthening of flux lines occurs below the conductor, and the conductor will
be pushed upwards (figure-IV).
Now consider a single turn coil carrying a current as shown in the above figure. In view of the reasons
given above, the coil side A will be forced to move downwards, whereas the coil side B will be forced to
move upwards. The forces acting on the coil sides A and B will be of same magnitude. But their
direction is opposite to one another. As the coil is wound on the armature core which is supported by
the bearings, the armature will now rotate. The commentator periodically reverses the direction of
current flow through the armature. Therefore the armature will have a continuous rotation.
Specifications:
 Standard nominal voltage = 12 V
 No load speed = 100 rpm
 No load current = 2A
 Nominal speed = 100 rpm
 Nominal torque = 70 Nm.
 Nominal power = 8 watt
 Max power = 70 watt
 Max. efficiency = 80 %
 Fig. technical drawing of 12 volt geared motor

3. Bevel Gear Pair:

Looking at bevel gears from the differences in helix angles, they can be generally classified into
straight bevel gears, which do not have helix angles, and spiral bevel gears (including zero bevel
gears), which do have helix angles. However, because of the fact that manufacture facilities for
straight bevel gears are becoming rare and the fact that straight bevel gears teeth cannot be
polished, making spiral bevel gears which can be polished superior in terms of noise reduction,
spiral bevel gears are likely to become more common in the future.

Bevel gears can be generally classified by their manufacturing methods, namely the Gleason
method and Klingenberg method, which each have differing teeth shapes, and presently most
gears use the Gleason method. Incidentally, all gears manufactured by KHK use the Gleason
method.

4. 12 volt lead acid battery

The lead-acid battery was invented in 1859 by French physicist Gaston Planté and is the oldest
type of rechargeable battery. Despite having a very low energy-to-weight ratio and a low energy-
to-volume ratio, its ability to supply high surge currents means that the cells have a relatively large
power-to-weight ratio. These features, along with their low cost, make it attractive for use in
motor vehicles to provide the high current required by automobile starter motors.

Figure. 12 volt lead acid battery

 Specifications

Voltage: 12 Volt
Capacity: 2 Ah
Type: Sealed Lead Acid Battery
Length: 5.95"
Width: 2.56"

DESIGN OF COMPONENTS
5.1 General Design Consideration In Machine :-
Following are the general consideration in designing a machine component.
1) Type of Load and stresses caused by the load.
The load on a machine component may act in several ways due to which stresses are set-
up. The load acting on the frame is the steady loads i.e. the weight of machine itself. The cutter is acted
by various forces. Due to this load and forces internal stresses are set up.
2) Motion of parts on kinematics of the machine.
The successful operation of any machine depends upon the simplest arrangement of the
parts, which will give the required motion. The machine is capable to withstand the rotary & vibratory
motion.
3) Selection of Material.
It is essential that the designer should have thorough knowledge of the properties
of the material under working condition. The important characteristics of the materials are strength,
durability, weight, resistance of wear and corrosion ability to cost or hardened machinability. Fro the
induced stresses on the components we have selected the required materials from design data book.
4) Form & Size of part.
Form and size are based on judgment the smallest particles cross-section may be used but
it may be checked that stresses include in the designed cross-section are safe. On basis of required forces
acting on the parts of machine who have designed the required sizes of arts, which is shown in Chapter
5.
5) Frictional-Lubrication and Resistance.
There is always loss of power due to friction. It is there fore, essential that a careful
attention must be given to the matter of lubrication of all surfaces, which move in the contact with other.
Following are the parts, which requires lubrication.
1. Ball bearings
2. Adjustable cutter arm
3. Adjustable cutter height
4. Back axle bearing
5. Pulley shaft
Flexible shaft does not require any lubrication.
6) Convenient & Economical Features.
In design ratings features of machine should be carefully studied. The starting controlling
and stopping level should be located on the basis of convenient handling. The adjustment for wear must
be provided expelling various take up devices and arranging them that the alignment of part is
preserved.
7) Safety of Operation.
Some machines are dangerous to specially those, which are up to ensured production at a
maximum rate. Therefore any moving part of the machine, which is within the zone of the worker, is
considered an accident hazard & may lead to injury so the safety appliances should be used. Likewise
for cutter there must be protective cover to the both cutter which must be adjustable cover.
8) Workshop facility.
A design engineer should be familiar with the limitations of his employers workshop in
order to avoid necessity of having work operation and to draft methods for casting, handling and
machining special parts.
On the basis of material procured from the workshop, operations on .lathe, welding,
grinding, drilling by using tools like hacksaw blade, bastard files, single point cutting tool the required
machine is being fabricated.
9) Number Of Machine To Be Manufactured
The engineering and shaft cost, which are called fixed charges, are distributed over the
no. of articles to be manufactured. And order calling for a small no. of products will not permit an undo
expense in the workshop processes so that the designer could restrict his specification and standard
parts.
5.2 Design as per Sugar Cane Cutting Machine
5.2.1 Design of Pulley (On centrifugal stress consideration )
Designing the pulley on the basis of centrifugal stress consideration.
let D = Diameter of driven pulley.
N1 = Speed of P.T.O. shaft.
1) We know centrifugal stress
2
σ =ρ×v
Assume, tensile stress  = 0.7 x 106 N/m2
Density of CI,  = 7250 Kg/m3
0.7 x 106 = 7250 x v2
v = 9.83 m/s
π dN
Velocity of Pulley v = 60
 π ×d×1600
9.83 = 60 (from machine design by Khurmi and Gupta )

9.83×60
d = π ×1600
= 0.1173 m
d = 117.3 mm
For power ranges 0.7 - 3.5 kW
Width of belt (b) = 13 mm
Thickness of belt (t) = 8 mm
( Type of belt - A - A - 525 mm long )
2) Width of smaller pulley
The width of smaller pulley or face of pulley (b)
b = 1.25 x k ( k=17, from machine design by Khurmi and Gupta )
= 1.25 x 17
= 21.25
b = 25 mms

5.2.2 Design of Driven Pulley Shaft

Let d= diameter of shaft
N2 = speed of pulley
Power transmitted = 1.119 KW
RPM of pulley = 1600 (from machine design by Khurmi and Gupta )
We known that torque acting on the pulley shaft
3
P×60 1. 119×10 ×60
=
T= 2 N 2 2×π ×1600

 6.67 Nm
Assuming 25 % overload
T pulley = 1.25 x 6.67
= 8.35 Nm  10Nm
Also the axial load on the pulley
 2 T 2×10
=
ft =
D p 0.2
= 100 Nm
and bending moment, M = ft x Dp /2
= 100 x 0.2 /2
= 10 Nm
Now we also the equivalent twisting moment

Te = √ M2 +T 2
Te = √[ 10]2+[10]2
Te = 14.14 Nm  15 Nm
This twisting moment is equal to
π
×f S ×d 3
Te = 16
d = 13.65 mm  14 mm
Take, d = 19mm (std. Diameter )
Assuming fluctuating load condition, take diameter of shaft = 25 mm and the shaft is made in step
having bearing size 20 mm.
Design of Key
From data book for the range of shaft dia. 22 to 33 key cross section are as follows :
i.e. width b = 8 mm
Height h = 7 mm
5.2.3 Cutting Force and Power
We know that the force required to cut is given by
F = Area x Shear stress
Where A = area of sugarcane
& A =  /4 d2
and d = dia. of sugarcan = 30 mm
and considering the shear stress of a sugarcane is 2 N/mm2
Force f = A x fS
=  /4 d2x fS
=  /4 (30)2x 2
 = 1413.71 N
This force f is required to cut one sugarcane by one cutter. But our machine has two
cutters and at a time 2- stems are cut
Forced required to cut 2 stems
F=2xf
= 2 x 1413.71
= 2827 .42 N
Therefore power required for cutting
P = force x velocity
1.119 x 103 = 2827.42 x V
V = 0.3957 m/s
= 23.7460 m/min
 25 m/min
Since the velocity of the machine calculated is high. And there are many difficulties in
moving the machine in the field, such as the weight of the machine itself and the field condition
( including human condition).
Therefore, considering V = 15 m/min = 0.25 m/sec.
DET DESCRIPTION MATERIAL QTY. SIZE REMARK
NO.
1 MAIN PLATE MS 1
2 STEEL CUTTER (WOOD STD 2 1D32 X OD 300 X
-SAW) 3MM THK
3 DOWEL PIN STD 2 DIA 16 X30 LONG
4 SPINDLE EN-8 2 DIA 80 X 115 LG.
5 WASHER MS 2 DIA 80 X 12 THK
6 SPRING LOCK WASHER STD 2 TO SUIT M20 DIA
BOLT
7 ALLEN BOLT STD 2 M20 X 30 LG
8 OIL SEAL STD 2 32 X 52 08
9 ALLEN BOLT STD 8 M10 X 25 LG
10 TAPER ROLLER BEARING STD 2 SKF NO - 30205
11 BALL BEARING STD 2 SKF NO - 6004Z
12 V BELT 'A' SECTION STD 1 A - 525 MM LONG
13 V BELT PULLY A SEC, CI 2 DIA 70 X 25 LG
14 WASHER MS 2 DIA 70 X 25 LG
15 ALLEN BOLT STD 2 M12 X 25 LG
16 HOUSING MS 2 FABRICATED
16A HOUSING BODY MS 2 DIA 65 X 50 LG
16B PLATE MS 2 75 X 115 X 12 THK
17 HOUSING MS 1 DIA 65 X 50 LG WITH DRILL
HOLE
18 KEY MS 2 5 X 4 X 20 LG
SELECTION OF ENGINEERING MATERIALS

Introduction to Roles & Responsibilities of Materials Engineer:

Some of Materials Engineer responsibilities are :

1) Design Process:

a) Drawing the basic design.

b) Proper selection of materials :

Selection according to different parameters such as :

 Mechanical loads,
 Wear,
 Electrical insulation,
 Thermal properties
 Availability & cost.

This includes: Selection of the proper manufacturing processes,

2) Proper choice (selecting) of substitute (alternative) materials when needed.

3) Contributing and evaluating materials tests results,

4) Studying and composing materials data sheets before placing an order,

5) Enhancing the performance of the materials by carrying out research

activities.

1.Introduction to Materials Selection:

One of the most challenging task of materials engineer is the proper selection of
the material for a particular job, e.g., a particular component of a machine or
structure. An engineer must be in a position to choose the optimum
combination of properties in a material at the lowest possible cost without
compromising the quality.

Factors affecting the selection of materials:

(i) Component shape:

The shape and size of a component has great effect on the choice of the
processing unit which ultimately effects the choice of the material. To make it
more clear, we consider an example, let the best possible production method is
selected, under given conditions, it is die casting, obviously, now the choice of
the material becomes limited, i.e. one can only choose materials with lower
melting points, e.g. aluminium, zinc, magnesium and thermoplastics.

(ii) Dimensional tolerance:

There are some materials which can be finished to close tolerance while others
cannot. Obviously, the required dimensional tolerance for finished components
will, influence the choice of materials.

(iii) Mechanical properties:

To select a suitable material for specific conditions, all mechanical properties,

e.g.,

toughness, hardness, strength, etc. guide us.

(iv) Fabrication (Manufacturing) requirements:

Method of processing of the material also affects the properties of a component,
e.g., forged components can be stronger than the casted components. Different
types of working processes may also give different types of fibre structure.
However, investment casting can provide precise dimensions at low cost in
comparison to machine operations.

Note: fabrication requirements are: castability, i.e., ease in casting a material,

weldability- ease in welding the material, machinability-ease to machine a
material, formability-ease to form a material, hardenability etc.

(v) Service requirements:

Service requirements are :

 dimensional stability,

 strength,

 toughness,

 heat resistance,

 corrosion resistance,

 fatigue and creep resistance,

 electrical and thermal conductivity etc.

(vi) Cost :

(A) Cost of the material:

In most of the cases, the cost of raw material accounts about 50 % of the
finished cost. Obviously, the cost of the material is a major factor which
influences the choice of the material or process. We must note that the use of
cheaper material will not always reduce the final cost of the component or
product. Use of cheaper material may be associated with higher processing cost
due to large number of operations to be performed and also more scrap. We can
easily see that this sometimes makes the overall cost more than that of
expensive raw material in combination with low processing cost due to lesser
number of operations and lesser scrap. The type of material affects the detailed
aspect of design and hence the choice of material as well as the process is
selected at the early design state e.g. whether the material is to be joined by
spot welding, screws or rivetes, must be decided at the design state.

(B) Cost of processing:

In most of the industries, the processing cost (labour cost) and other costs such
as overhead costs account for about 50% of the production cost. Overhead cost
in automatic industries is much more than the other costs. If one can somehow
reduce all such costs, the total production cost will automatically reduce.

(vii) Availability of the material:

We may find that sometimes the availability of the material becomes a

governing factor. When the desired material supply is limited, then a costly
material which is available in ample quantity may be chosen.

Procedure for materials selection:

The selection of an appropriate material and its subsequent conversion into a

useful product with desired shape and properties can be a rather complex
process. Nearly every engineered item goes through a sequence of activities
that includes:
design material selection process selection production evaluation
and possible redesign

Summary:

The selection of a specific material for a particular use is a very complex

process. However, one can simplify the choice if the details about:

(i) operating parameters,

(ii) manufacturing processes,
(iii) functional requirements
(iv) cost considerations are known.

 Therefore, when we talk about choosing materials for a component, we

take into account many different factors. These factors can be broken down into
the following areas:

Material Properties
The expected level of performance from the material
Material Cost and Availability
Material must be priced appropriately (not cheap but right) Material must be
available (better to have multiple sources)

Processing
Must consider how to make the part, for example: Casting
Machining Welding
The effect that the service environment has on the part The effect the part has
on the environment
The effect that processing has on the environment

2. Introduction to Engineering Materials:

Basic Classifications of Materials:

The basic factors for classifications of materials in material science and

engineering are:

(i) The chemical composition of the material,

(ii) The mode of the occurrence of the material in the nature,

(iii) The refining and the manufacturing process to which the material
is subjected prior it acquires the required properties,

(iv) The atomic and crystalline structure of material.

(v) The industrial and technical use of the material.

According to Budinski : materials may be classified as shown below:

Materials
Generally, materials engineering may be classified into the following
categories:

1) Metals and alloys.

2) Ceramics.

3) Polymers.

4) Composites.

5) Advanced materials: such as semiconductors, biomaterials, smart

materials, and nanoengineered materials.

Metals and alloys:

Metals are elements which have free valence electrons which are responsible
for their good thermal and electrical conductivity. Metals readily loose their
electrons to form positive ions. The metallic bond is held by electrostatic force
between delocalized electrons and positive ions.

Note : Engineering metals are generally Alloys. There are metallic materials
formed by mixing two or more elements, such as:
 Mild steel Fe + C
 Stainless steel Fe + C + Cr + Mn …etc.
o C improves strength
o Cr improves the corrosion resistance
…etc.

 Classification of metals and alloys:

 Ferrous:
Such as : Plain carbon steel, Alloy steel, Cast iron,

 Nonferrous:
Such as : Light Alloys (Al, Mg, Ti, Zn), Heavy Alloys (Cu, Pb, Ni), Refractory
Metals (Mo, Ta, W), Precious metals (Au, Ag, Pt)

 General properties:

 High electrical conductivity.

 High thermal conductivity.

 Ductile and relatively high stiffness.

 Toughness and strength.

 They are ready to machining, casting, forming, stamping and

welding. Nevertheless, they are susceptible to corrosion.  Applications:

 Structures: buildings, bridges, etc.

 Automobiles: body, springs, engine block, etc.

 Airplanes: engine components, fuselage, landing gear assembly,

etc.

 Trains: rails, engine components, body, wheels

 Machine tools: drill bits, hammers, screwdrivers, saw blades, etc.

 Electrical wiring.
  Magnets

 Examples:
 Pure metal elements (Cu, Fe, Zn, Ag, etc.)

ADVANTAGES AND DISADVANTAGES

ADVANTAGES
1. Harvesting time will be lower.
2. Efficient work is done by using this machine.
3. Low number of labors are required for whole operation.
4. Cost of harvesting is very less as compared with manual harvesting.

DISADVANTAGES
1. Efficient work is not done.
2. The cost of machine will be more.
3. Shortage of experienced labor.
 REFERENCE
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Research gate Vol. 30(5): 727-739, 18 January 2015.
[2] Design of Sugarcane Harvesting Machine G. D. Shelke S. S. Borikar, M. P. Awathale A. P. Khante,
IJIRST –International Journal for Innovative Research in
Science & Technology| Volume 1 | Issue 11 | April 2015.
[3] Review Paper on Different Aspects of Sugarcane Harvesting Methods for Optimum Performance,
Rohit J. Masute, S. S. Chaudhari, S. S. Khedkar, B. D.
Deshmukh, International Journal of Research in Engineering and Applied Sciences (IJREAS) Vol. 02,
Issue 01, Jan 2014.
[4] Sugar-cane harvesting machine design “in the field” Lidiane Regina Narimoto MSca, Robin
Burgess-Limerick PhD, Proceedings 19th Triennial Congress of
the IEA, Melbourne 9-14 August 2015.
[5] Visible Losses in Mechanized Harvesting of Sugarcane Using the Case IH A4000 Harvester Carmen
Maria Coimbra Manhães*, Ricardo Ferreira Garcia, Francisco Maurício Alves Francelino, Delorme
Correa Junior, Cristóbal Soto Solano, Helenilson de Oliveira Francelino, American Journal of Plant
Sciences, 2014, 5, 2734-2740. [6] Li Lixin, Chen Weixu, Cheng Zhiqing, Li Shangping, Liu Dongmei.”
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[7] MCcarThy.The integration of Sensory Control for Sugar cane Harvesters, Doctor of
Philosophy,America, 2003.
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