Final Report Darren Durkan g00277204

A THESIS SUBMITTED FOR THE DEGREE OF BACHELOR OF ENGINEERING
(HONOURS) IN MECHANICAL ENGINEERING

AT THE SCHOOL OF ENGINEERING
GALWAY-MAYO INSTITUTE OF TECHNOLOGY, IRELAND
Development of a front mounted mower for Malone Farm Machinery
AUTHOR
Darren Durkan
SUPERVISOR
Gabriel Costello
CO-SUPERVISOR
Dr Thomas Roche
DEPARTMENT OF MECHANICAL & INDUSTRIAL ENGINEERING
GALWAY-MAYO INSTITUTE OF TECHNOLOGY
1
DECLARATION OF ORIGINALITY
May, 2014
The substance of this thesis is the original work of the author and due reference and
acknowledgement has been made, when necessary, to the work of others. No part of this
thesis has been accepted for any degree and is not concurrently submitted for any other
award. I declare that this thesis is my original work except where otherwise stated.
(Signature of Candidate)
2
Dedication
The author would like to dedicate this thesis to my family and friends for their support
over the last few years of college.
3
Abstract
4
Acknowledgements
The author would like to thank all of the following people for their help and advice
throughout the compiling of this thesis.
 Gabriel Costello, project supervisor who gave me vast amounts of advice and
support in compiling of this thesis.
 Family and friends
5
Contents
Development of a front mounted mower for Malone Farm Machinery.........................1
AUTHOR...............................................................................................................................1
DEPARTMENT OF MECHANICAL & INDUSTRIAL ENGINEERING..........................1
DECLARATION OF ORIGINALITY..............................................................................2
Abstract..................................................................................................................................4
Contents..............................................................................................................................15
List of Figures.....................................................................................................................24
List of Tables......................................................................................................................27
CAD: Computer Aided Draughting /Computer Aided Design............................................28
1 Introduction..................................................................................................................29
Figure 1.2 Feraboli front mower mounting.........................................................................30
1.1 Aims......................................................................................................................30
1.2 Objectives..............................................................................................................30
1.3 Structure................................................................................................................31
1.4 Background...........................................................................................................32
Feraboli Agricultural Technologies.................................................................................33
Figure 1.4 Feraboli Agricultural Technologies...................................................................33
Patent license agreement...................................................................................................34
1.5 Agricultural machinery development in Mayo.....................................................34
1.6 Mowing conditioning process...............................................................................35
Figure 1.6 Front Mounted and Rear Mounted Mowers.......................................................36
Figure 1.7 Malone Pro Cut 960c..........................................................................................36
6
Figure 1.8 Butterfly Combinations......................................................................................37
2 Literature review..........................................................................................................38
2.1 History of Mowers................................................................................................38
2.1.1 Introduction of drum and disc mowers..........................................................38
Figure 2.1 Piet Zweggers experimenting with the first concept of a front mounted drum
mower..................................................................................................................................39
2.1.2 Evolution of modern mower/conditioner.......................................................40
2.2 Typical drive train.................................................................................................41
Figure 2.4 Typical front mower drive train arrangement....................................................41
2.3 Attachment Methods.............................................................................................42
2.4 Conditioning systems............................................................................................43
2.5 John Deere 131 front Mounted Mower.................................................................44
Figure 2.10 Figure 2.11 John Deere 131 Front Mounted Mower........................................44
2.6 Pottinger front mounted mower............................................................................45
Figure 2.12 Pottinger Front mounted mower.......................................................................45
2.7 Krone.....................................................................................................................46
Figure 2.13 Krone Easy Cut front Mower...........................................................................46
2.8 Kverneland Tarrup 3632 FT..................................................................................47
Figure 2.14 Kverneland Tarrup Front Mounted Mower......................................................47
2.9 Claas 3500 FC PROFIL........................................................................................48
Figure 2.15: Claas Front Mounted Mower..........................................................................48
2.10 Comparison of existing mowers........................................................................50
3 Materials and Method..................................................................................................52
3.1 Product design and development..........................................................................52
3.1.1 Overview........................................................................................................52
3.1.2 Design:...........................................................................................................52
3.1.3 Manufacturing:...............................................................................................53
7
3.1.4 Marketing.......................................................................................................53
3.2 Product development process................................................................................54
Figure 3.1 Kressy’s product development plan...................................................................54
Figure 3.2 Eppingers product development plan.................................................................54
Figure 3.3 Product development plan for front mounted mower........................................55
Research..............................................................................................................................55
Concept development........................................................................................................56
Design development...........................................................................................................56
Manufacture.......................................................................................................................56
Testing.................................................................................................................................56
3.3 Concept development............................................................................................57
3.3.1 Mind mapping................................................................................................57
Figure 3.4 Mind map...........................................................................................................57
3.3.2 Design idea 1.................................................................................................58
Figure 3.5 Idea 1 Piston Damper Mechanism......................................................................58
Advantages.........................................................................................................................58
3.3.3 Design idea 2.................................................................................................59
Figure 3.6 Idea 2 Scissors lift..............................................................................................59
Advantages...........................................................................................................................59
Disadvantages......................................................................................................................59
3.3.4 Design idea 3.................................................................................................60
Advantages...........................................................................................................................60
Disadvantages......................................................................................................................60
4 Materials and method...................................................................................................61
4.1 Design development..............................................................................................61
4.1.1 Use of 2D CAD in the design process...........................................................61
CAD benefits include:.........................................................................................................61
8
Figure 4.1 More recent developments in mower bed drive train arrangement....................63
4.2 Use of 3D CAD in the design process..................................................................64
4.2.1 Receipt of original CAD model.....................................................................65
4.2.2 Editing............................................................................................................66
Figure 4.3 Side panels..........................................................................................................67
4.2.3 Main Assembly..............................................................................................68
Figure 4.4 Mower front view showing symmetrical position of Feraboli unit to mower and
offset pivot point..................................................................................................................69
4.2.4 Pivot point......................................................................................................69
Figure 4.5 Main structural support member........................................................................69
Figure 4.6 Mower bed and spinal box section.....................................................................69
Figure 4.7 assembly tabs and slots.......................................................................................71
Figure 4.8 Pivot point assembly box section at 8o...............................................................71
Figure 4.9 Pivot point assembly mated at box section at 0o................................................72
Figure 4.10 Pivot Point assembly mated to box section at 4o..............................................72
4.2.5 Drive mechanisms..........................................................................................73
Figure 4.12 Central gear box...............................................................................................73
Figure 4.13 2D views of central gear box mounting brackets.............................................74
Figure 4.14 Gear box mount initial design..........................................................................74
Figure 4.15 2D views of central gearbox final design.........................................................74
Figure 4.16 Gear box mount in final position......................................................................75
4.2.6 Side mounted gear box..................................................................................76
Figure 4.17 Initial design side mounted gear box bracket...................................................76
Figure 4.18 Side gear box mounting bracket final design..................................................77
4.2.7 Baffle plate.....................................................................................................78
Figure 4.19 Baffle plate.......................................................................................................78
9
4.2.8 Conditioning system......................................................................................79
4.2.9 Front gate hinge.............................................................................................80
Figure 4.24 Hinge system....................................................................................................80
4.2.10 Pulley safety guard........................................................................................80
4.2.11 Specification change to 3m cutting bed.........................................................81
Figure 4.26 3-metre cutting bed...........................................................................................81
4.2.12 Box section structural spine...........................................................................83
4.2.13 Conditioner drive shaft..................................................................................83
4.2.14 Tensioner bracket...........................................................................................84
Figure 4.29 Tensioner bracket.............................................................................................84
4.2.15 Safety guard bracket......................................................................................84
4.2.16 Side gate.........................................................................................................85
Figure 4.31 Side gate...........................................................................................................85
4.2.17 Driveshaft guard............................................................................................85
4.2.18 Driveshaft guard location bracket..................................................................86
Figure 4.33 Driveshaft guard location bracket....................................................................86
4.2.19 Grass boards...................................................................................................87
Figure 4.34 Initial grassboard design...................................................................................87
Figure 4.35 Final design of grassboard................................................................................88
4.3 Design calculations...............................................................................................89
4.3.1 To find centre of gravity of mower................................................................89
Figure 4.37 Free body diagram............................................................................................89
Loads are as following:......................................................................................................89
P1= 230N.............................................................................................................................89
P2=2697.75N.......................................................................................................................89
4.3.2 To calculate shock loading............................................................................90
Assuming tractor travelling at 30 kmph..............................................................................91
10
7.77m/s.................................................................................................................................91
By equation of motion:......................................................................................................91
56.52 m/s 2=a......................................................................................................................91
Multiple of static loading on pin due to shock impact= 56.527/9.81= 5.76...................91
4.3.3 To specify bolts for alternative design option.(attachment of pivot point). . .92
Area = π x ( d)2 4...................................................................................................................92
Area = π x (0. 01)2 4 .............................................................................................................92
A= 7.8539 x 10-5m2..............................................................................................................92
Assuming Young’s modulus of steel to be 210 GPa...........................................................92
Se= ka kb kc kd ke kf Se’....................................................................................................93
Se’= [ 0.566 – 9.68 e-5 x 520] x 520...................................................................................93
4.3.4 Conditioner shaft calculation.........................................................................95
Power = (T 1 –T2) v...........................................................................................................95
Sub in for T2.......................................................................................................................95
Power = (T1 – T1 e−μα ) v................................................................................................95
V= 10.54 m/s.......................................................................................................................95
Output power.....................................................................................................................95
Rated output power(Gear box Spec sheet) = 19.3 da N∙m.............................................95
Output speed = 1000 rpm x 2 π /60s.............................................................................95
Output speed = 104.71 rad/s............................................................................................95
Power= 20.2 kW.................................................................................................................95
Power = (T1 – T1 e−μα ) v................................................................................................95
T1= 3564.5 N.......................................................................................................................96
For conditioner pulley.......................................................................................................96
T1= 3564.5 N.......................................................................................................................96
T2= 1625.84N......................................................................................................................96
Diagrams.............................................................................................................................96
11
F1X = 3564.5 x cos 53 = 2145.17 N....................................................................................96
Forces in the y- direction...................................................................................................97
Figure 4.40 Shear force and bending moment diagrams in y-direction...............................97
Forces in the x direction....................................................................................................98
Figure 4.41 Shear force and bending moment diagrams in x-direction...............................98
Max bending moment..........................................................................................................98
= (2846.74 – 1363.54 + 2145.17 – 885.5) x 118x10-3.........................................................99
Minimum diameter under static loading is 39 mm.......................................................100
Under fatigue loading......................................................................................................100
Assuming steady torque of 323.65 N ∙ m...........................................................................100
Minimum diameter under fatigue loading is 54 mm....................................................101
4.3.5 Pivot pin static.............................................................................................102
Figure 4.42 Schematic of pivot pin....................................................................................102
Transverse shear................................................................................................................103
A factor of safety of 75.15 under static loading.............................................................103
4.3.6 Pivot pin ANSYS Analysis..........................................................................104
P=F/A................................................................................................................................104
The stress intensity (figure 4.45) was then plotted and τmax of 21.21MPa was read of the
plot. This was the used to determine a factor of safety using BS080M40 cold drawn steel
(Table A-16) with a yield strength of 430 MPa. Using the following equation below a
factor of safety of 10.13 under static loading was found. A factor of safety of 10.13 under
static loading.....................................................................................................................104
4.3.7 Pivot point impact load................................................................................105
4.3.8 Impact Loading Analysis.............................................................................107
P=F/A................................................................................................................................107
A factor of safety of 1.76 under impact loading was determined................................107
4.3.9 Pivot point Static load on 36mm pin...........................................................108
12
4.3.10 Static loading ANSYS analysis on 36mm...................................................109
As the author felt that a factor of safety of 1.76 was adequate under impact loading, it was
thought that a smaller pin would be sufficient. A pin of 36mm diameter was analysed, at
static loading, a pressure of 0.73471MPa was applied to the pin......................................109
P=F/A................................................................................................................................109
A factor of safety of 7.48 under static loading...............................................................109
4.3.11 Impact loading on 36mm pin.......................................................................110
A factor of safety of 10.56 under impact loading..........................................................110
4.3.12 Impact Loading ANSYS analysis................................................................111
P=F/A................................................................................................................................111
A factor of safety of 1.3 was obtained from impact loading on a 36 mm pin.............111
4.3.13 ANSYS analysis on pivot point...................................................................112
A factor of safety of 33.2 under static was determined................................................113
Impact loading...................................................................................................................113
To verify results...............................................................................................................115
4.4 Manufacturing.....................................................................................................116
4.4.1 Production....................................................................................................116
4.4.2 Research & Development............................................................................117
4.4.3 Metal cutting................................................................................................117
4.4.4 Press brake...................................................................................................118
4.4.5 Tube bender.................................................................................................118
4.4.6 Welding process...........................................................................................119
4.4.7 Painting........................................................................................................120
4.4.8 Final assembly.............................................................................................121
4.4.9 Final testing..................................................................................................121
5 Health and safety.......................................................................................................122
5.1 Introduction to health and safety.........................................................................122
13
5.2 Safety in the workshop........................................................................................122
5.3 Safety measures incorporated into the front mounted mower............................123
5.3.1 Other safety measures considered................................................................124
Results................................................................................................................................125
Figure 0.1 Malone front mounted mower FM 3000..........................................................125
Discussion/conclusion.......................................................................................................126
Figure 0.8 Butterfly Combinations....................................................................................127
Highlight the over engineering..........................................................................................128
Recommendations............................................................................................................130
Make a front mower prototype.......................................................................................131
Project Plan........................................................................................................................135
References..........................................................................................................................136
Appendices.........................................................................................................................138
P=F/A................................................................................................................................138
FX= 0.73471 x (17.32 x 212) = 2697.73N........................................................................138
Impact loading on 40mm pin.............................................................................................138
TOTAL VALUES..............................................................................................................138
FX= 4.2315 x (10 x 212)=8970.78N.................................................................................138
Static loading on 36mm pin...............................................................................................139
Impact loading on 36 mm pin............................................................................................139
Static loading on pivot point..............................................................................................140
TOTAL VALUES..............................................................................................................140
FX=1.11256x700 = 778.79N.............................................................................................140
Impact loading on pivot point............................................................................................140
TOTAL VALUES..............................................................................................................141
FX= 6.408 x700 = 4485.8N...............................................................................................141
14
Contents
Development of a front mounted mower for Malone Farm Machinery.........................1
AUTHOR...............................................................................................................................1
DEPARTMENT OF MECHANICAL & INDUSTRIAL ENGINEERING..........................1
DECLARATION OF ORIGINALITY..............................................................................2
Abstract..................................................................................................................................4
Acknowledgements................................................................................................................5
Contents................................................................................................................................6
List of Figures.....................................................................................................................24
List of Tables......................................................................................................................27
Glossary..............................................................................................................................28
CAD: Computer Aided Draughting /Computer Aided Design............................................28
1 Introduction..................................................................................................................29
Figure 1.1 Malone Conditioner unit....................................................................................29
1.1 Aims......................................................................................................................30
1.2 Objectives..............................................................................................................30
1.3 Structure................................................................................................................31
1.4 Background...........................................................................................................32
Malone Farm Machinery..................................................................................................32
Feraboli Agricultural Technologies.................................................................................33
Patent license agreement...................................................................................................34
15
1.5 Agricultural machinery development in Mayo.....................................................34
1.6 Mowing conditioning process...............................................................................35
Figure 1.6 Front Mounted and Rear Mounted Mowers.......................................................36
Figure 1.8 Butterfly Combinations......................................................................................37
2 Literature review..........................................................................................................38
2.1 History of Mowers................................................................................................38
2.1.1 Introduction of drum and disc mowers..........................................................38
mower..................................................................................................................................39
2.1.2 Evolution of modern mower/conditioner.......................................................40
2.2 Typical drive train.................................................................................................41
2.3 Attachment Methods.............................................................................................42
2.4 Conditioning systems............................................................................................43
2.5 John Deere 131 front Mounted Mower.................................................................44
2.6 Pottinger front mounted mower............................................................................45
2.7 Krone.....................................................................................................................46
2.8 Kverneland Tarrup 3632 FT..................................................................................47
2.9 Claas 3500 FC PROFIL........................................................................................48
2.10 Comparison of existing mowers........................................................................50
3 Materials and Method..................................................................................................52
16
3.1 Product design and development..........................................................................52
3.1.1 Overview........................................................................................................52
3.1.2 Design:...........................................................................................................52
3.1.3 Manufacturing:...............................................................................................53
3.1.4 Marketing.......................................................................................................53
3.2 Product development process................................................................................54
Research..............................................................................................................................55
Concept development........................................................................................................56
Design development...........................................................................................................56
Manufacture.......................................................................................................................56
Testing.................................................................................................................................56
3.3 Concept development............................................................................................57
3.3.1 Mind mapping................................................................................................57
Figure 3.4 Mind map...........................................................................................................57
3.3.2 Design idea 1.................................................................................................58
Advantages.........................................................................................................................58
3.3.3 Design idea 2.................................................................................................59
Advantages...........................................................................................................................59
Disadvantages......................................................................................................................59
3.3.4 Design idea 3.................................................................................................60
Advantages...........................................................................................................................60
Disadvantages......................................................................................................................60
17
4 Materials and method...................................................................................................61
4.1 Design development..............................................................................................61
4.1.1 Use of 2D CAD in the design process...........................................................61
CAD benefits include:.........................................................................................................61
4.2 Use of 3D CAD in the design process..................................................................64
4.2.1 Receipt of original CAD model.....................................................................65
4.2.2 Editing............................................................................................................66
4.2.3 Main Assembly..............................................................................................68
4.2.4 Pivot point......................................................................................................69
4.2.5 Drive mechanisms..........................................................................................73
4.2.6 Side mounted gear box..................................................................................76
18
4.2.7 Baffle plate.....................................................................................................78
4.2.8 Conditioning system......................................................................................79
4.2.9 Front gate hinge.............................................................................................80
4.2.10 Pulley safety guard........................................................................................80
4.2.11 Specification change to 3m cutting bed.........................................................81
4.2.12 Box section structural spine...........................................................................83
4.2.13 Conditioner drive shaft..................................................................................83
4.2.14 Tensioner bracket...........................................................................................84
4.2.15 Safety guard bracket......................................................................................84
4.2.16 Side gate.........................................................................................................85
Figure 4.31 Side gate...........................................................................................................85
4.2.17 Driveshaft guard............................................................................................85
4.2.18 Driveshaft guard location bracket..................................................................86
4.2.19 Grass boards...................................................................................................87
4.3 Design calculations...............................................................................................89
4.3.1 To find centre of gravity of mower................................................................89
Loads are as following:......................................................................................................89
19
P1= 230N.............................................................................................................................89
P2=2697.75N.......................................................................................................................89
4.3.2 To calculate shock loading............................................................................90
Assuming tractor travelling at 30 kmph..............................................................................91
7.77m/s.................................................................................................................................91
By equation of motion:......................................................................................................91
56.52 m/s 2=a......................................................................................................................91
Multiple of static loading on pin due to shock impact= 56.527/9.81= 5.76...................91
4.3.3 To specify bolts for alternative design option.(attachment of pivot point). . .92
Area = π x ( d)2 4...................................................................................................................92
Area = π x (0. 01)2 4 .............................................................................................................92
A= 7.8539 x 10-5m2..............................................................................................................92
Assuming Young’s modulus of steel to be 210 GPa...........................................................92
Se= ka kb kc kd ke kf Se’....................................................................................................93
Se’= [ 0.566 – 9.68 e-5 x 520] x 520...................................................................................93
4.3.4 Conditioner shaft calculation.........................................................................95
Power = (T 1 –T2) v...........................................................................................................95
Sub in for T2.......................................................................................................................95
Power = (T1 – T1 e−μα ) v................................................................................................95
V= 10.54 m/s.......................................................................................................................95
Output power.....................................................................................................................95
Rated output power(Gear box Spec sheet) = 19.3 da N∙m.............................................95
Output speed = 1000 rpm x 2 π /60s.............................................................................95
Output speed = 104.71 rad/s............................................................................................95
Power= 20.2 kW.................................................................................................................95
Power = (T1 – T1 e−μα ) v................................................................................................95
T1= 3564.5 N.......................................................................................................................96
20
For conditioner pulley.......................................................................................................96
T1= 3564.5 N.......................................................................................................................96
T2= 1625.84N......................................................................................................................96
Diagrams.............................................................................................................................96
F1X = 3564.5 x cos 53 = 2145.17 N....................................................................................96
Forces in the y- direction...................................................................................................97
Forces in the x direction....................................................................................................98
Max bending moment..........................................................................................................98
= (2846.74 – 1363.54 + 2145.17 – 885.5) x 118x10-3.........................................................99
Minimum diameter under static loading is 39 mm.......................................................100
Under fatigue loading......................................................................................................100
Assuming steady torque of 323.65 N ∙ m...........................................................................100
Minimum diameter under fatigue loading is 54 mm....................................................101
4.3.5 Pivot pin static.............................................................................................102
Transverse shear................................................................................................................103
4.3.6 Pivot pin ANSYS Analysis..........................................................................104
P=F/A................................................................................................................................104
The stress intensity (figure 4.45) was then plotted and τmax of 21.21MPa was read of the
plot. This was the used to determine a factor of safety using BS080M40 cold drawn steel
(Table A-16) with a yield strength of 430 MPa. Using the following equation below a
factor of safety of 10.13 under static loading was found. A factor of safety of 10.13 under
static loading.....................................................................................................................104
4.3.7 Pivot point impact load................................................................................105
4.3.8 Impact Loading Analysis.............................................................................107
21
P=F/A................................................................................................................................107
A factor of safety of 1.76 under impact loading was determined................................107
4.3.9 Pivot point Static load on 36mm pin...........................................................108
4.3.10 Static loading ANSYS analysis on 36mm...................................................109
As the author felt that a factor of safety of 1.76 was adequate under impact loading, it was
thought that a smaller pin would be sufficient. A pin of 36mm diameter was analysed, at
static loading, a pressure of 0.73471MPa was applied to the pin......................................109
P=F/A................................................................................................................................109
A factor of safety of 7.48 under static loading...............................................................109
4.3.11 Impact loading on 36mm pin.......................................................................110
A factor of safety of 10.56 under impact loading..........................................................110
4.3.12 Impact Loading ANSYS analysis................................................................111
P=F/A................................................................................................................................111
A factor of safety of 1.3 was obtained from impact loading on a 36 mm pin.............111
4.3.13 ANSYS analysis on pivot point...................................................................112
A factor of safety of 33.2 under static was determined................................................113
Impact loading...................................................................................................................113
To verify results...............................................................................................................115
4.4 Manufacturing.....................................................................................................116
4.4.1 Production....................................................................................................116
4.4.2 Research & Development............................................................................117
4.4.3 Metal cutting................................................................................................117
4.4.4 Press brake...................................................................................................118
4.4.5 Tube bender.................................................................................................118
4.4.6 Welding process...........................................................................................119
4.4.7 Painting........................................................................................................120
22
4.4.8 Final assembly.............................................................................................121
4.4.9 Final testing..................................................................................................121
5 Health and safety.......................................................................................................122
5.1 Introduction to health and safety.........................................................................122
5.2 Safety in the workshop........................................................................................122
5.3 Safety measures incorporated into the front mounted mower............................123
5.3.1 Other safety measures considered................................................................124
Results................................................................................................................................125
Figure 0.8 Butterfly Combinations....................................................................................127
Highlight the over engineering..........................................................................................128
Recommendations............................................................................................................130
Make a front mower prototype.......................................................................................131
Project Plan........................................................................................................................135
References..........................................................................................................................136
Appendices.........................................................................................................................138
P=F/A................................................................................................................................138
FX= 0.73471 x (17.32 x 212) = 2697.73N........................................................................138
Impact loading on 40mm pin.............................................................................................138
TOTAL VALUES..............................................................................................................138
FX= 4.2315 x (10 x 212)=8970.78N.................................................................................138
Static loading on 36mm pin...............................................................................................139
Impact loading on 36 mm pin............................................................................................139
Static loading on pivot point..............................................................................................140
TOTAL VALUES..............................................................................................................140
23
FX=1.11256x700 = 778.79N.............................................................................................140
Impact loading on pivot point............................................................................................140
TOTAL VALUES..............................................................................................................141
FX= 6.408 x700 = 4485.8N...............................................................................................141
List of Figures
Figure 1.1 Malone Conditioner unit....................................................................................29

Figure 1.3 Malone Farm Machinery....................................................................................32
Figure 1.5 Mc Hale Fusion 3...............................................................................................34
mower..................................................................................................................................39
Figure 2.2 One of the first Drum Mowers to Operate Figure 2.3 Modern day Mower
40
Figure 2.5 Three point linkage attachment Figure 2.6 A-frame attachment method.......42
Figure 2.7 V-shaped roller conditioner Figure 2.8 Standard tine conditioner.................43
Figure 2.9 Conditioning unit in operation...........................................................................43
24
Figure 3.4 Mind map...........................................................................................................57
Figure 3.7 Idea 3 pivot point................................................................................................60
Figure 4.11 Final pivot point assembly design....................................................................72
Figure 4.20 Conditioning unit..............................................................................................79
Figure 4.21 End view of conditioner...................................................................................79
Figure 4.22 Conditioning hood............................................................................................79
Figure 4.23 Hood positional locking system.......................................................................79
Figure 4.25 Pulley safety guard...........................................................................................80
Figure 4.27 Bed mounting configuration.............................................................................82
Figure 4.28 Conditioner drive shaft.....................................................................................83
25
Figure 4.30 Safety guard bracket.........................................................................................84
Figure 4.31 Side gate...........................................................................................................85
Figure 4.32 Driveshaft guard...............................................................................................85
Figure 4.36 Grass board adjsuters........................................................................................88
Figure 4.38 Road Ramp.......................................................................................................90
Figure 4.39 Bolts layout.......................................................................................................94
Figure 4.43 Shear force and bending moment diagrams under static loading...................102
Figure 4.44Pressure distribution on a pin..........................................................................104
Figure 4.45 Max shear stress under static loading.............................................................104
Figure 4.46 Max stress and deflection...............................................................................104
Figure 4.47 Shear force and bending moment diagrams under impact loading................105
Figure 4.48 Max shear stress under impact loading..........................................................107
Figure 4.49 Max stress and max deflection.......................................................................107
Figure 4.54 Local hotspot of Max stress............................................................................112
Figure 4.56 Figure 4.57 Local hotspot of Max stress........................................................113
Figure 4.59 Process layout.................................................................................................116
Figure 4.60 Plasma cutter..................................................................................................117
Figure 4.61 Bandsaw.........................................................................................................117
Figure 4.62 Press brake......................................................................................................118
Figure 4.63 V-blocks.........................................................................................................118
Figure 4.64 Tube bender....................................................................................................118
26
Figure 4.65 Side gate.........................................................................................................118
Figure 4.66 Conditioner shaft............................................................................................119
Figure 4.67 Jig...................................................................................................................119
Figure 4.68 Spraying booth...............................................................................................120
Figure 4.69 Priming booth.................................................................................................120
Figure 4.70 Curing booth...................................................................................................120
Figure 4.71 Stacking for assembly....................................................................................120
Figure 4.72 Assembly of the conditioning unit.................................................................121
Figure 5.1 Safety components of Malone front mower.....................................................123
List of Tables
Table 2.1 Comparison table.................................................................................................49
27
Glossary
CAD: Computer Aided Draughting /Computer Aided Design
CAM: Computer Aided Manufacturing
CNC: Computer Numerical Control
FAT: Feraboli Agricultural Technologies
FEA: Finite Element Analysis
GMIT: Galway-Mayo Institute of Technology
MFM: Malone Farm Machinery
PTO: Power Take Off
ANSYS: Engineering simulation software.
28
1. Introduction
The author must complete and submit a major project report in order to complete the final
year in his degree in Mechanical Engineering in Galway-Mayo Institute of Technology.
The Major Project is worth 10 credits of the final grade. The author has chosen to complete
a project in the agricultural engineering sector as he comes from a rural background and
has a strong interest in this area of engineering.
The project will be completed in conjunction with Malone Farm Machinery (MFM), an
agricultural engineering company in Co. Mayo. Following a number of meetings with the
company management to discuss the possibility of completing a project with the firm, it
was suggested that the author carry out design work for the manufacture of a planned new
addition to the company’s mower conditioner range. The existing model range includes the
Pro Cut 960c trailed conditioner mower and the Pro Cut 800 side mounted disc mower.
The firm wishes to also offer a front mounted machine, as it has identified that there is
room in both the Irish and European market for another manufacturer’s product of this
particular configuration.
In order to economically bring this project to fruition in as short a timescale as possible,

the firm has entered into a business relationship with Feraboli Agricultural Technologies
(FAT), an Italian engineering company. The two firms have agreed to a patent-swapping
arrangement in which MFM can avail of a FAT designed front mower mounting (Figure
1.2) and adapt it to facilitate the conversion of a MFM trailed mower to a front mounted
model. In return, FAT is licensed to use the MFM design for conditioning units in its own
mowers (Figure 1.1).
29
Figure 1.1.1 Malone Conditioner unit
Figure 1.1.2 Feraboli front mower mounting
1.1 Aims
The aim of this project is to use the
knowledge and skills that the author has gained
and developed over the past four years at college and apply them to a real life engineering
development scenario. The project chosen is in the author’s area of interest and may be
directly beneficial in his future career as a mechanical engineer.
The content of the project will entail:
 Research of the concept.

 Design and development of a new mower model.
 Completion of the project within the time constraints and to a high standard.
 Involvement in manufacture and assembly.
 Involvement in testing of a prototype machine.
1.2 Objectives
 Meet with the client on regular basis for advice and direction.
 Become familiar with the specific product area through research.
 Carry out concept design processes.
 Carry out product development processes.
 Create working drawings.
 Carry out engineering calculations.
 Perform ANSYS analysis.
30
 Assist in manufacture and assembly.
 Assist in testing.
1.3 Structure
Background
The background is an introduction to the project and a description on the business

relationship that MFM and FAT have agreed upon. It includes a discussion on the
suitability of Mayo to agricultural machinery development and background information on
the mowing/conditioning process.
Literature Review
The literature review contains the research undertaken in relation to the project, which
includes a history of the evolution of drum and disc mowers and detailed research on the
most common front mower models currently available on the market. Due to the nature of
the topic, much of this research was based on information found from the internet,
manufacturer’s brochures, journals, and product videos. As far as possible, peer-reviewed
engineering publications and books were also accessed.
Materials and method
This section will include a detailed description of how the project was brought from the
concept stage, through CAD modelling, calculations, ANSYS, manufacturing, assembly
and testing.
Discussion/conclusion
In this section the author will analyse and evaluate the development process of the
designed modifications and how successfully the aims and objectives were achieved. The
problems encountered will also be discussed along with alternative routes which could
have been taken to address these. The author will discuss all the main aspects of the project
and speculate on what would be done differently if the project was to be undertaken again.
31
1.4 Background
Malone Farm Machinery
Malone Farm Machinery is a dynamic company which was established in 1999 to service a
growing agricultural market, and operates in a 1700m2 premises (Figure 1.3) at Ballyglass,
Claremorris, Co Mayo [1]. The firm employs 20 full-time skilled operatives in the
workshops along with 7 other staff carrying out managerial, design, purchasing, sales and
administration roles. The manufacturing areas are equipped for laser cutting, welding,
folding, spraying, final assembly and testing/quality control. All of the major engineering
processes are carried out in-house but a number of specialised items for the firms designs
are provided by subcontractors. Examples include cast steel bearing housings, high tensile
linkage pins and hardened steel mower cutting blades.
Figure 1.1.3 Malone Farm Machinery
Malone Farm Machinery manufactures a wide range of agricultural equipment including

post-drivers, grass toppers, log splitters and forage equipment such as mowers. In recent
years the firm has expanded its share of the forage machinery market considerably by
launching its own design of self loading wagons. The firm works closely with the farming
community and constantly modifies and updates its products reflecting feedback and
suggestions for improvement from customers. The ranges of products are promoted widely
throughout Ireland and the company has won a reputation for quality of design,
manufacture and after-sales backup.
It is considered by the management of MFM that there is an opening in the Irish market for
a locally manufactured front-mounted mower which will compete with imported
32
implements from such firms as Krone and John Deere. Further in the future, MFM would
hope to eventually emulate the international sales expansion of Mc Hale Engineering by
gaining a market share in the global mower-conditioner sector.
Feraboli Agricultural Technologies
Feraboli Agricultural Technologies (FAT) is an Italian engineering company that

manufactures and sells agricultural equipment throughout Italy and is based in Coremona,
a city situated in the Po valley in the north of the country [2]. This region has historically
always had a predominately agriculture based economy and thus is a good location for an
agricultural engineering facility.
There are 150 employees working in the Feraboli factory (Figure 1.4) manufacturing a
range of farming equipment. Products include soil preparation implements such as power
harrows and seeders, forage equipment including mowers and round balers and feeding
equipment such as mixing wagons.
Figure 1.1.4 Feraboli Agricultural Technologies
33
Patent license agreement
Each of these firms holds patents on their designs, MFM for their conditioning system and
FAT for their mounting system. They have decided that they will both benefit
economically from a business agreement which will allow each to use the other’s design in
this particular instance.
A patent confers upon its holder the right to exclude others from exploiting (making,
using, selling or importing) the patented invention or design, except with the consent of the
owner of the patent. The patent is only valid for a limited time and is a form of 'industrial
property’ which can be assigned, transferred, licensed or used by the owner [3].
According to the Irish Exporters Association [4], the function of the patent is to protect the
inventor’s rights, while returning benefit to society. The Irish Patents Office [3] explains
that patents are territorial, and an Irish patent is only valid in Ireland.
Patents are an integral part of the engineering design and manufacturing sector and play a
key role in enabling innovative designers or manufactures to profit from their new ideas
and skills without the fear of immediate plagiarism.
1.5 Agricultural machinery development in Mayo

There are a number of well established companies manufacturing agricultural machinery in
County Mayo. With the local economy being primarily farming based and there already
existing an engineering skills base, the area is well suited to further developments in this
field.
In Ballinrobe the well known firm of Mc Hales have become one of the market leaders in
silage baling equipment and export to Europe, New
Zealand and Australia. Their latest innovation is their
own design Fusion Baler (Figure 1.5), an all-in-one
variable chamber baler wrapper. Also within the
county, Major Engineering in Ballyhaunis
34
Figure 1.1.5 Mc Hale Fusion
3
manufactures a range of equipment from slurry handlers to sports pitch mowing machines.
Perhaps one of the most important phases in the successful bringing to market of
agricultural machinery is the field testing procedure, and Mayo provides ideal scenarios for
adequate satisfaction of this step in the process. Due to the wide variation of terrain types,
ground conditions, grass quality, field size and field accessibility, the county provides a
suitable test bed for prototype machine development and innovation. Indeed, the fact that a
machine has been developed and tested within the West of Ireland environment has proven
to be an important selling point to potential customers from further afield.
1.6 Mowing conditioning process

In the modern era of intensive agricultural production, it is necessary to cut and make
silage as quickly and efficiently as possible. This is particularly important in a country
with a highly variable weather pattern such as Ireland. Other factors which will impact on
the efficiency of field based farming operations include the suitability of the equipment to
the often hilly nature of the Irish landscape and the fragmented pattern of the field
structure. Any machine designed for the Irish market must be able to automatically adapt
to the rapidly changing and undulating terrain experienced in practice. These conditions
also require that the operating machinery is over-engineered (compared for example to that
required for large flat terrain conditions) in order to successfully cope without frequent
failure or an over extensive and expensive maintenance regime.
The bulk silage making process is broken down into two main operations; the grass is cut
and laid into swathes by conditioning mowers and is then lifted by a forage harvester
which can load trailers for transport to storage. The entire process is commonly completed
over a two to four day time span as normal practice is for the cut grass to be allowed to
wilt according to the wishes of the farmer.
The ranges of mowers commonly used throughout Europe are mainly based on three
distinct design concepts:
 Trailed conditioner mower (Figure 1.7)

 Rear side mounted mower (Figure 1.6)
 Front mounted mower(Figure 1.6)
35
Each of these types is produced by a range of manufactures in cutting widths of
approximately 3m. In many instances large scale agricultural contractors would have
models of each type in their fleet in order to cope as efficiently as possible with different
types of terrain, size of fields and accessibility to location. In rural Ireland access to fields
on many farms is hindered by road, lane and gate width. In other parts of the country, such
as the extensive flat land areas of Meath and Kildare these problems do not arise and
machines with the largest throughput can be utilised.
Figure 1.6 Front Mounted and Rear Mounted Mowers
Figure 1.7 Malone Pro Cut 960c
Where suitable, combinations of the mower types can be mounted to the same tractor of
adequate capability. As can be seen in (Figure 1.8) two side mounted models can even be
used in conjunction with a front mounted mower (known as a butterfly combination). This
configuration can cut a swathe up to 8m wide and can thus dispose of extensive areas of
grass efficiently in a short period of time. Obviously a highly powered tractor equipped
with both front and rear power take off (PTO) is required for this system to be used. The
36
cost savings for such efficient grass cutting can be passed on to the farmer. Additionally,
the time savings can be substantial allowing best use of the short windows of opportunity
which are often all that is available in the variable summer weather pattern.
Figure 1.8 Butterfly Combinations
Traditionally, agricultural implements have been rear mounted and make use of the rear
PTO shaft which has been universally fitted to all tractors. Front PTO drives are a
relatively modern innovation in tractor design but increasingly have become more popular
with farmers. This allows additional connection of a front mounted mower thus doubling
mowing capacity. This is the key reason why the front mounted mower is an increasingly
desirable implement for the large farmer or the agricultural contractor.
37
2 Literature review
In the literature review the author will analyse the requirements to be considered when
designing an attachment system for mounting a mower conditioner to the front of a tractor.
In order to successfully carry this out it will require investigation and research into the
methods of operation of a number of existing front mounted mowers. The author will
therefore examine the design and operation of currently available mowers and analyse how
their attachment systems, flotation mechanisms and PTO drives are successfully integrated
into a mechanically efficient, trouble free and low maintenance assembly. Due to the
nature of the project much of this information will be of necessity based on manufacturer
supplied data, but peer reviewed publications and academic journals will be referred to
where possible.
2.1 History of Mowers
2.1.1 Introduction of drum and disc mowers.

From the 1850’s mechanical grass mowers were based upon the finger bar system which
consisted of a large number of triangular blades oscillating as the machine advanced into
the base of the grass stems [4]. However, with the increasing use of fertilisers and
subsequent heavy crops, this system was painfully inadequate due to the inherent low
speed of cut and tendency for blades to clog either due to bluntness, stone damage or
simply by being overwhelmed with the crop bulk.
The finger bar mower was made virtually obsolete in the mid 1960’s by the invention of
the ‘cyclo mower’ by Piet Zweggers, as this device incorporated the basic concepts of the
drum and disc mowers that are on the market to this day. Following license agreement
with companies such as Fahr and Kuhn, patents were established in over 26 different
countries worldwide and a revolution in mowing was established.
38
Figure 2.6 Piet Zweggers experimenting with the first concept of a front mounted drum mower.
Zweggers continued with the development of his ideas and in 1970 manufactured a mower
which, although still powered from the rear PTO shaft, was mounted on the front of the
tractor (Figure 2.1) .This was huge step in mower development and in recognition of his
contribution to the process, the major manufacturer Kuhn designated their mower series as
Kuhn PZ.
39
2.1.2 Evolution of modern mower/conditioner.
Mowing technology has continued to evolve, driven by the necessity to keep up with the
pace of crop bulk development due to more effective fertilising regimes and tillage
practice. Not only are modern crops of grass much heavier than in the past but the actual
grass blade profiles have been developed requiring more powerful machinery (both
tractors and mowers) in order to efficiently process fields of forage. Modern tractors have
a much larger power output and can supply higher speed and torque to both rear and front
PTO drives in order to service externally powered implements. The latest machinery such
as the John Deere 131 front mounted mower is able to achieve cutting speeds of 1000 rpm
and ground speeds of 6 to 15 km/h depending on the crop volume [5]. Additionally,
modern mowers are designed so that they can efficiently operate regardless of the terrain
or the condition of the grass. The progress in mowing technology for even farmers
operating on a smaller scale is illustrated by comparison of the machines shown in Figures
2.2 and 2.3.
Figure 2.7 One of the first Drum Mowers to Operate Figure 2.8 Modern day Mower
40
2.2 Typical drive train.
The layout of the drive train to the mower bed is commonly as shown in Figure 2.4. Rotary
power is supplied by connection to the tractor PTO shaft and then fed directly to a 90o
bevel gearbox centrally located on the mower. Each end of the shaft incorporates a
universal joint thus accommodating the constant tractor-mower varying relationship in
both the vertical and horizontal planes. A second shaft transmits the drive across the top of
the mower to another bevel gearbox which supplies the power downwards to the gear train
in the oil-filled bed of the mower. This horizontal shaft is fitted with universal joints in
order to accommodate the ‘floating’ of the mower about the pivot point as it encounters
variations in the ground surface. Different designs of conditioning system may be fitted
and driven directly from the second gearbox or more usually by a system of pulleys. The
rotating discs on which the cutting blades are mounted are driven from the circular bed
gears.
Figure 2.9 Typical front mower drive train arrangement
41
2.3 Attachment Methods.
All the attachment systems connect the mower to the three point linkage on the tractor
front with the drive supplied by telescopic shaft. In some systems the mower is simply
connected directly to this linkage (Figure 2.5), but due to the lack of visibility of the
mating parts by the operator , it may be difficult to align the tractor components with the
mower components. This is a disadvantage of this system.
Other methods incorporate an A-frame (Figure 2.6) as an intermediate component in order

to facilitate ease of mounting/dismounting. This is basically a ‘quick hitch’ system which
latches the permanent A-frame on the rear of the mower to a removable A-frame which is
attached to the three point linkage on the front of the tractor. Positive connection of the
mower to the tractor is achieved by simple male/female locking [6] and can be completed
much more easily by the operator from the seat of the tractor. Once the mower is mounted,
the PTO shaft and hydraulic hoses can be manually coupled.
Figure 2.10 Three point linkage attachment Figure 2.11 A-frame attachment method
42
2.4 Conditioning systems
The quality of silage will depend to a large degree on the wilting regime which the cut
grass is subjected to. Achieving a good wilt can produce more profitable returns for the
farmer as the quality of winter feed will play a vital role in the growth and development of
the livestock. Variable weather conditions can seriously disrupt planned wilting time as the
farmer and contractor must operate during dry weather if possible when ground conditions
are optimal. This may lead to the shortening of wilting time as the process is rushed to get
the cut grass off the field before rain. Therefore the conditioning unit on the mower will
play a pivotal role in the wilting time and consequently the silage quality. The conditioner
aids in the removing of the wax coating from the crop to allow the moisture from inside
the grass to escape. Proper conditioning of the grass will allow the wilting time to be
halved. Normally the unit can be adjusted to vary the degree of conditioning applied to the
grass and may simply involve the repositioning of a restricting plate.
The conditioner has a further role as it leaves the swathe ruffled thus allowing the wind
and sun to penetrate in order to achieve a quality wilt. The standard tine conditioner
(Figure 2.8) as found on the Malone Pro Cut 960c is suited to high volumes of grass while
the V-shaped roller type (Figure 2.7) as used in models manufactured by Feraboli is more
suited to softer crops such as alfalfa which are more common in Italy.
Figure 2.12 V-shaped roller conditioner Figure 2.13 Standard tine conditioner
The V-shaped roller conditioner drives the grass in between the rollers allowing a gentler
alternative to steel tine conditioning and gives protection to the leaf and nutrients of the
crop [8]. The standard tine conditioner
provides a more rugged conditioning process
and as can be seen in Figure 2.9, the grass is
passed between the restricting plate and the
rotationg steel tines providing aggresive
abrasion of the leaf. Figure 2.14 Conditioning unit in operation
43
2.5 John Deere 131 front Mounted Mower
The John Deere 131 front mounted mower (Figure
2.10) uses the A-frame attachment system to
mount to the front of the tractor and it can be
raised or lowered using hydraulic rams. The
mower has a cutting width of up to 3.1 metres [7].
Drive is taken directly from the PTO through two Figure 2.15 John Deere 131 Front
universal joints into a central gearbox on the unit Mounted Mower
which outputs at 90o to an additional bevel gearbox at the side of the mower which
supplies power down to the bed housing the cutting discs. Pulleys are mounted on an
auxiliary output shaft in order to belt-drive the conditioner unit.
In order to enable the cutting bed of the mower to follow the undulating ground surface, a
flotation mechanism must be incorporated into the design.
On less expensive models the trapezium

suspension shown uses springs to keep
downward pressure on the cutting bed.
When an obstacle is encountered the mower
pivots and the bed is lifted over the
Figure 2.16 Trapezium suspension obstruction.
The 131 model dispenses with springs and a hydro-pneumatic suspension system is
employed to allow the machine to follow the
contours of the ground or prevent damage to
the crop stubble due to the tractor sinking in
soft ground. Double rod cylinders are used in
conjunction with an accumulator in order to
provide both flotation and lifting of the bed. The Figure 2.17 Hydro-pneumatic suspension
cylinders work independently allowing the

mower body to pivot from side-to-side for optimum operation on uneven ground. The
tractor driver can adjust flotation by manipulation of a valve in order to maintain constant
ground pressure within a recommended range.
44
2.6 Pottinger front mounted mower
The Pottinger Nova Cat 131 front mounted mower (Figure 2.13) uses a highly developed
system of springs in order to control flotation. The firm’s active carrier alpha motion
headstock was a world first [8], and allows the mower unit to respond immediately to the
shape of the ground. An additional benefit of this design is that the A-frame system used
by this mower is attached straight on the three point linkage on the tractor and thus the
mower centre of gravity is brought closer.
The headstock of the mower is mounted on three ball joints which enable the bed of the
mower to follow the contour of the ground closely controlled by two powerful springs
keeping uniform pressure on the bed. The mower is claimed to float over every bump and
down into every hollow.
As with the John Deere model, drive to the cutting bed is supplied from the PTO via
central and side mounted gearboxes.
Figure 2.18 Pottinger Front mounted mower
45
2.7 Krone
The well known Krone Easy Cut 32 CV Float [9] shown at Figure 2.14 is a front mounted
mower which is connected to the tractor using the direct three point linkage locking
system.
In order to provide flotation, a system using a headstock as a central pivot point with an
integrated coil spring is employed. The spring maintains a constant pressure in order to
keep the bed of the mower in close contact with the ground in undulating terrain [11].
Uniform ground pressure is achieved due to the relationship between the suspended mower
body and spring resistance.
Again, power is supplied to the mower bed from the PTO through two right angle gear
boxes. The conditioner is driven direct from the lower gearbox and the blades are mounted
on oval discs which allow a generous cutting overlap.
Figure 2.19 Krone Easy Cut front Mower
46
2.8 Kverneland Tarrup 3632 FT
The Kverneland Tarrup 3632 FT (Figure 2.15) [10] is a available with a cutting width of
3.2m and is fitted with Kverneland’s unique semi-swing steel tine conditioning system.
The tines are restrained from swinging freely into a position perpendicular to the rotor by
virtue of their mounting position on the rotor. The three point linkage of this mower is
connected directly to that of the tractor resulting in the unit being located relatively close
to the tractor front. The mower is raised or lowered by a central hydraulic ram.
The machine automatically adapts to a variation in ground profile by using a flotation

method based on the employment of two large springs to keep the cutting bed close to the
ground.
Drive to the cutting bed is provided using the conventional transmission system of central
and side mounted 90o gearboxes along with pulley drive to the conditioning system.
Figure 2.20 Kverneland Tarrup Front Mounted Mower
47
2.9 Claas 3500 FC PROFIL
This Claas front mounted mower (Figure 2.16) has a cutting width of 3 to 3.4 m and uses
the A-Frame system to connect to the tractor [11].
The machine employs an active float system to achieve a clean and close cut of the sward.
The system is comprised of large volume pressure accumulators which are connected to
two suspension cylinders. These work in conjunction with a single pivot point system to
allow the bed of the mower to adjust regardless of the tractor positioning. If ground
conditions change, the tractor driver can change the system response from the cab by
simply adjusting a single acting spool valve.
The tractor driven PTO shaft delivers power to a centrally mounted 90o gearbox , from
which twin shafts are coupled (in opposing directions) to side mounted 90 o bevel
gearboxes which transmit rotation to the bed mounted cutting discs and conditioning
system respectively.
Figure 2.21: Claas Front Mounted Mower
48
Krone Easy Cut 32 Cv Kverneland Tarrup
John Deere 131 Pottinger Nova Cat 351 Claas 3500 FC Profil
float 3632 FT
Recommended
Power 100 Hp 80 Hp 82 Hp 80Hp 100Hp
Requirements
PTO Speed 1000 Rpm 1000 Rpm 1000Rpm 1000Rpm 540 Rpm
Cutting
3.1m 3.46m 3.14m 3.2m 3.4m
Width
Cutting discs 8 8 7 8 8
Attachment
System A-frame A-frame 3-point linkage direct 3-point linkage direct A-frame
Suspension
System Adjustable Hydro Head stock Spring Spring controlled Double acting
Counter Springs
pneumatic controlled hydraulics
Conditioning 54 V-shape steel

V-shaped steel tine V-shaped steel tine V-shaped steel tine
System tines Semi Swing steel tines
Drive
90 degree bevel 90 degree bevel 90 degree bevel
Train 90 degree bevel 90 degree bevel
gearboxes gearboxe gearboxes
gearboxes gearboxes
Pulley driven Gear box driven Pulley driven
Pulley driven 2 speed gear box driven
conditioners conditioner conditioners
conditioners driven conditioner
Weight 1300 kg 1195 kg 980 kg 1205 kg 1220 kg

Min. cut
20mm 50mm 30mm 20mm 40mm
height
Table 2.1 Comparison table
49
2.10 Comparison of existing mowers
The author researched the most common mower conditioners in the Irish market place and
investigated the specification of each model. The most important features have been
displayed in Table 2.1 in order to facilitate easy comparison.
The models researched were the John Deere 131, Krone Easy Cut 32 CV Float,
Kverneland Tarrup 3632 FT, Pottinger Nova Cat 351 and the Claas 3500 FC Profil.
Although all of the models use basically the same drive-train configuration, there are some
differences in how power is supplied to the conditioning system. The machines which
differed from the standard method of driving the conditioner by a pulley system were
Krone and Claas models. Both of these models use conditioners directly gear driven from
the side mounted bevel gear box. The Class machine has the ability to be set at either of
two speeds in order to achieve different degrees of conditioning.
The conditioning systems in all of the machines used v-shaped steel tines to aggressively
bruise the cut grass and ruffle it to produce a swathe in optimal condition for
wilting/drying. The Kverneland machine is fitted with its unique design of ‘semi swing’
tines which are restrained from fully revolving by their mounting on the rotor, resulting in
an increase of the conditioning effect.
With regards to tractor power recommended, all of the machines require a minimum of
80hp with the John Deere and Claas recommending a minimum of 100hp. These figures of
course only apply if a front mounted mower is used in isolation. Cutting width varied
significantly from the 3.1m of the John Deere to the 3.46m of the Pottinger. Three of the
models researched used A-frames for tractor connection with the Krone and Kverneland
utilising direct three point linkage.
Of particular interest to many farmers or contractors who may on many occasions

experience soft ground conditions is the machine weight. There is quite a variation of
weight between the models, the Krone being lightest at 980 kg while the John Deere model
is heaviest at 1300 kg. This will have a large impact on the tractor front axle loading and
may not suit many locations. Additionally, the extra loading will have long term wear
implications for tyres, wheel bearings and steering mechanisms.
Most operators would be keenly interested in minimising downtime particularly due to

commonly occurring repair/maintenance procedures such as blade replacement. All of the
50
models other than the John Deere are designed with quick change blade mountings. The
Kverneland blades are fitted to circular discs which the manufacturer claims are less
susceptible to damage. The free space at all times between the discs will allow stones and
debris to be immediately ejected out, without creating a blockage which could result in
shock loads to the transmission and possible triggering of shear mechanisms. All of the
other models use elliptical discs on which the blades are mounted. Adjacent discs are fixed
at 90o to each other so that blades (mounted at each end of the major axis) cannot clash as
they revolve. The manufacturers claim that this design promotes more efficient grass
cutting as the blade overlap is generously increased [10].
Of particular interest to operators normally mowing on large even terrain is the ability to
cut as low as possible. In this respect the John Deere machine has the optimal ability with
a minimum cut height of 20mm with the others cutting down to 30-50mm.
Perhaps the main area in which the researched models differed was in the design and
operation of the flotation system. This is probably the area which poses the most difficulty
for a design engineer to successful address. The different methods used to enable the
mower to follow the contours of the ground employ various configurations of hydro-
pneumatic and hydraulic systems or spring controlled mechanisms, or combinations of all
of these.
51
3 Materials and Method
3.1 Product design and development
3.1.1 Overview
According to Ulrich and Eppinger [6], the economic success of most manufacturers
depends on the identification of customer needs and then the rapid production of items
which can satisfy these needs at low production cost. In the same vein, the Royal Academy
of Engineering [14] identifies that engineering design encompasses the identification of a
clearly identifiable need, a creative response to that need, and the delivery of a system or
product that meets the need. The overall process from the initial identification of a market
opportunity to the manufacture and sale of the finished article can be termed ‘product
development’. Successful product development in the engineering sector will involve the
interaction of various professionals within any manufacturing organisation, along with
regular input from the prospective end-user, in this case the farming community.
Large national or international manufacturers may have specific staff or often complete
departments with specific roles in the product development process. However, in smaller
engineering firms such as Malone Farm Machinery, many staff may have interdisciplinary
roles carrying out a number of functions within the organisation and it may be more useful
in this instance to refer to ‘functions’ rather than ‘disciplines’.The development process for
this project will continuously evolve with each of the contributing areas in the company
responding to input from the others. The company functions central to the overall scheme
can be summarised as:
3.1.2 Design:
The author will play a key role in this function, working under the supervision of the
resident engineer to produce an efficient working design for an attachment system to
mount a MFM trailed mower conditioner to a tractor front. The product will play a
functional role only and the aesthetics of the design will be very much a minor
consideration. Ergonomic considerations will be limited to ease of initial system
installation/removal and access for manual connection of hydraulic hoses. There will be no
electrical or software system design requirement. Design work will be carried out
primarily using Creo Parametric software.
52
3.1.3 Manufacturing:
This function will also involve input from the author including the specification of
components and materials and furnishing of the same to company management for
ordering. He will also be responsible for the preparation of work schedules, cutting lists
and methods of work to be used to complete the project. The author also intends to become
involved as much as possible in the ‘hands on’ aspect of the engineering solution, making
use of workshop skills learned in fabrication and assembly.
3.1.4 Marketing
As this function can be considered to encompass all interaction between the manufacturer
and buyers/prospective buyers, MFM have already initialised the process by identifying
farmer needs and the market opportunity for the firm’s own front mounted mower. This
interaction will continue with the involvement of local agricultural contractors in the field
trial and testing stages of the production process, and will take place outside the time-span
of the author’s involvement. However, the author intends to play an important role in the
marketing function by producing a new sales brochure specifically promoting the new
front mounted mower model.
53
3.2 Product development process
The author has researched a number of texts dealing with the area of product development.
The model proposed by Ulrich and Eppinger [13] is illustrated in Figure 3.2 and the
procedure devised by Kressy in Figure 3.1. Although different terminology is used by the
authors, the process recommended by each follows the same basic sequential route from
research through to end product.
Figure 3.22 Kressy’s product development plan
Figure 3.23 Eppingers product development plan
54
Using these models as a basis, the author has structured a product development plan
specifically tailored to suit the successful design of this particular type of product in the
agricultural engineering environment (Figure 3.3).
This process will be followed in order to bring this product to fruition.
Research Concept Design Manufacture Testing

development development
Initial Cutting Quality assurance
specification Initial design Parametric
Fabricating Workshop testing
Sketches/rende modelling
Manufacturer’s
rings Welding Field trialling
facilities ANSYS
Review/modify Assembly
End user Stress
calculations Machining
Existing
products
Figure 3.24 Product development plan for front mounted mower
Research
In the research phase of this product development plan the author received the initial
specification of the project from MFM. From this the product background was researched
as demonstrated in the literature review.
The manufacturing facilities at MFM have already been discussed and the use of these will
be further investigated in this report when the methods of manufacture and materials used
are addressed.
Similarly, the author’s research has also extensively investigated the current market with
regards to front mounted mowers and has reported on the relationship between MFM and
its present and prospective customers.
55
Concept development
The author conducted a series of mind mapping and brainstorming exercises in order to
help generate design ideas. Initial thoughts were then sketched and a matrix was formed
and used to rate the ideas against the reference criteria. The idea with the highest score was
brought forward to the next stage of concept development.
Design development
In this phase of the product development plan, the Creo parametric modelling package was
used to create 3D parts and generate a full assembly to enable the stakeholders to view the
mower in its entirety and to simulate operation before the manufacturing stage would
begin. This phase would prove to constitute the major element in the author’s involvement
with the overall project. Also included in this stage would be the completion of
engineering calculations to verify the integrity of the design and the use of ANSYS
software to provide stress analysis.
Manufacture
In this phase of the product development plan the manufacture of a prototype front mower
will take place using the workshop facilities at MFM and incorporating a number of
specialised components supplied by subcontractors.
Testing
A thorough quality control check of the machine will take place before it leaves the
workshop. This will include an evaluation of the functionality of machine as well as
physical checks of all components and assembly methods including quality of welding.
The actual functional testing of the machine will take place in a nearby field of grass
which has been previously used for evaluation purposes. If any shortcomings are identified
either in the mower assembly or in its performance, these will be addressed by further
action.
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3.3 Concept development
3.3.1 Mind mapping

A mind map is an influential technique used as tool that designers employ in the
generation of ideas. Originally developed by Tony Buzan [15], this technique is often used
by engineers to solve problems. The process of the mind map starts with the problem/idea
set in the centre of the page, and as the idea field is broadened the mind map develops into
a tree like structure.
Figure 3.25 Mind map
As shown in Figure 3.4, the author developed a mind map for the front mounted mower
consisting of all the main features that make up the machine. As this was prepared in
digital format the author could expand or amend it at any juncture as new design ideas
came to light.
57
3.3.2 Design idea 1
Feraboli linkage
Hydraulic cylinder
Malone
mower
Figure 3.26 Idea 1 Piston Damper Mechanism
Idea 1 entails connecting the mower unit and Feraboli front mounting using double acting
hydraulic cylinders. Each hydraulic cylinder connects the Feraboli unit to the main
structural spine of the mower (80x80x8mm box section) as shown in Figure 3.5. There are
a number of advantages and disadvantages to this design, outlined below:
Advantages
 Allows good ground tracking.

 Allows higher carrying of the mower for clearing swathe.
 The cylinders will also perform a shock absorbing function.
Disadvantages
 Requires hydraulic supply and control.

 Expensive components involved.
 Low structural integrity.
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3.3.3 Design idea 2
Figure 3.27 Idea 2 Scissors lift
Idea 2 uses a scissors mechanism to attach the Feraboli mounting to the body of the mower
as shown in Figure 3.6. Each of the ends of the scissor mechanism can slide in slotted
tracks and their movement is controlled by strong coil springs thus allowing a limited
range of movement to accommodate uneven terrain.
Advantages
 Economically efficient.
 Simply manufactured design.
 Robust, maintenance free design.
Disadvantages
 Limited ground tracking ability.

 Limited lifting height.
 Numerous wearing surfaces.
59
3.3.4 Design idea 3
Figure 3.28 Idea 3 pivot point
Idea 3 (Figure 3.7) combines a single pivot pin assembly on the mower main spine with a
mating pivot assembly on the Feraboli attachment. Relative movement between the mower
and Feraboli attachment is controlled by coil springs positioned as shown.
Advantages
 Strong robust design.

 Single pivot point allows mower to follow the ground.
 Controlled range of movement.
 Ease of in-house manufacture.
 Few wearing surfaces requiring little maintenance.
 Economically efficient.
Disadvantages
 Low damping effect.

 Complex design.
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4 Materials and method
As can be seen throughout the Literature Review, the author has carried out extensive
research into the technology and design of a number of front mounted mowers most
commonly employed for the harvesting of grass fodder in Irish agriculture. This work has
played a pivotal role in the author’s full understanding of how various aspects of design
can be combined with appropriate choices of materials and methods of manufacture in
order to produce a machine with qualities of efficiency in operation combined with
robustness, longevity, ease of maintenance and cost effectiveness.
4.1 Design development
4.1.1 Use of 2D CAD in the design process

The use of two dimensional (2D) computer aided draughting/design (CAD) software in
engineering design is well established and its utilisation has brought enormous advantages
to the design and manufacturing process, assisting in solving the visualisation, analytical,
development, economic and management problems associated with engineering design
work [16].
CAD benefits include:
 Increased speed of design.
 Absolute dimensional accuracy.
 Ease of modification and updating.
 Ability to incorporate archived and library material.
 Ease of data storage and transfer to other design and production team members.
 Ease of design and data transfer to and from partner companies, subcontractors,
specialist suppliers etc.
 Direct input to computer numerical control (CNC) machine tools via computer
aided manufacturing (CAM) software.
 Automatic linking to specialised software and databases for scheduling and costing.
 Reduction of overall production costs due to savings in design time, manufacturing

time and material wastage.
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In the initial research into the technology of mower design, the author found that his
understanding of the topic benefitted from the draughting of a simple isometric schematic
diagram (using AutoCad) illustrating a typical drive train arrangement (Figure 4.1).
Further investigation revealed that a number of manufacturers have updated the layout of
the mower cutting bed to an improved gearing arrangement. In the more modern designs
the large diameter gearwheels merely transfer the drive horizontally across the bed, and the
actual discs carrying the blades are driven directly by smaller auxiliary gears which mesh
with this horizontal transfer train [11]. This layout allows for lower rotational speeds
across the bed drive train, with the final gearing up to cutting speed achieved via meshing
with the auxiliary gears. The lowering of the speed of the large diameter gears in the bed
promotes quieter running and longer service life for both bearings and meshing teeth. The
auxiliary gears only drive one blade carrying disc each, and so are relatively lightly loaded.
Additionally, the resultant forward position of the discs promotes a good blade overlap.
With this knowledge, the author was able to quite easily and quickly modify his schematic
to reflect the more modern mower bed arrangement (Figure 4.1). Careful study of this
drawing will also reveal that the modified layout results in adjacent cutting discs rotating
inwardly towards each other which field experience has proven beneficial to efficient
mower operation.
These simple schematic layouts were completed by the author using Autodesk AutoCad
software which is an ideal tool for quickly producing 2D designs or modifying existing
drawings, and it is widely used throughout the global engineering industry. The ability to
rapidly modify existing drawings which can be easily read and understood on the
workshop floor has retained 2D draughting software as an important and extensively used
tool in the engineering industry, even as more diversely functional 3D software has come
to prominence [16].
In this instance, the updated schematic shown in Figure 4.1 was created from the author’s
original drawing (Figure 2.4) by the quite simple use of common AutoCad modify
commands such as erase, trim, scale, stretch, copy and offset.
In fact only one draw command was used by the author in the entire update process – the
arrows denoting direction of rotation and throughput of grass were drawn using polylines.
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Adjacent forward mounted disc-
pairs rotate inwards towards
each other, promoting more
efficient throughput of grass
Front mounted blade

carrying discs above
the bed are driven
directly from below
by auxiliary gears
Figure 4.29 More recent developments in mower bed drive train arrangement
4.2 Use of 3D CAD in the design process

Although basic Autocad has 3D capability, much more functional software is available for
true 3D design (more accurately termed ‘parametric solid modelling’). Three dimensional
63
CAD is now normally the starting point for product design [17]. The industry makes
extensive use of programs such as Autodesk Inventor, Siemens SolidEdge, SolidWorks or
PTC Creo and all are highly advanced tools assisting the creation, modification, analysis
and optimisation of design. These programs seem to broadly do the same job and produce
similar outputs; there is wide debate in the engineering community regarding the
comparative benefits, ease of use and steepness of learning curve of each.
Anecdotal evidence has influenced the author to surmise that the preference of an
individual designer may depend on whichever program he or she initially received
extensive training on, or whichever he or she happens to be the most proficient in using.
For the purposes of this project the author will use Creo, software on which he has
received training and has gained a reasonable degree of experience in its use. Additionally,
Creo is the software primarily used for engineering design by the host company MFM. The
author has found that a number of capabilities of the program have been particularly
beneficial to this project including:
 Visualisation of the new front attachment assembly as the design evolved was
possible, thus enhancing the communication of developing ideas and improved
information sharing between the author and other stakeholders such as MFM,
Feraboli and the project supervisor.
 The ability to easily create or modify clearances and interferences in order to

achieve efficient manufacture and assembly.
 Prevention of ‘component collision’ by the incorporation of warning systems and

automatic triggering of blocks within the program.
 Dynamic simulation could be used in order to validate the new assembly

performance, showing how it would operate in service and interact with the other
components when under load. This factor was vital in order to ensure that the three-
dimensional ‘floating’ requirement of the mower would not be compromised by the
new modifications. These dynamic ‘tests’ functioned as a substitute for constructing
working prototypes at greater cost in terms of time and finance.
Although neither the author nor the manufacturer MFM had access to the technology, it
should be noted that parametric modelling software also lends itself to the use of rapid
prototyping techniques. The author observed the value of this process in product
64
visualisation when completing an engineering exercise to manufacture a prototype
penknife, in the course of his studies at GMIT. A solid physical model of the new
attachment system assembly could be ‘3D printed’ – built up layer by layer in a polymer
material from CAD drawing scans. Due to the physical scale of the project in hand, this
technique is obviously beyond consideration by MFM. On account of the extremely rapid
development of 3D printing in recent years, the author is of the opinion that global
agricultural machinery manufacturers may already use this process as an aid to product
development. According to Darbyshire [16], these quickly produced models allow more
accurate visualisation of the finished product and facilitate evaluation of such aspects as
ergonomics and aesthetics in order that the design may be fine-tuned in readiness for
manufacture. Before the advent of such technology, model-making of new products was
generally the preserve of specialised subcontractors employed at extra cost.
4.2.1 Receipt of original CAD model

At the initiation of the project the author received from the MFM resident engineer an .stp
file of their Malone Pro Cut 960c trail mower. Due to the incompatibility issues between
the educational version of Creo and the industrial version, direct transfer of the complete
Creo file was impossible. This process immediately caused problems as vital parameters
were lost in the transfer. Datum points, planes, and axes were no longer valid, the model
was not fully constrained and the integrity of the assembly was compromised.
The author was therefore obliged to re-constrain the model with regard to axes and planes.
This proved to be a major task due to the size and complexity of the assembly and the
Figure 4.30 Malone Pro Cut 960c
relative inexperience of the operator, but after intensive application to the task in hand, the
model was successfully constrained and the design work proper could commence. Indeed,
the steep learning curve involved to overcome this initial problem may have proved very
65
beneficial for the further successful development of the product design using this particular
software.
4.2.2 Editing
A screenshot of the initial file received can be seen in Figure 4.2. After discussion with
MFM, the author gained an understanding of which components and parts of the trailed
mower could be eliminated from the new design, which parts would need to be modified
and a broad specification of parts which required designing from scratch.
The main components which were required to be removed from the model included:
 Drawbar
 Wheels
 Mounting brackets
 Top frame
 Suspension springs
 Hydraulic transports rams
 Rear hood
 Hydraulic slewing ram
 Drive shafts
 Gates
 Baffle plate
Once the model had been reduced to the operational format required, the author’s attention
could be turned to the Feraboli attachment structure. Again this was supplied as an .stp file
and as before the author was required to re-constrain the model before any modifications
could take place.
The author was now in a position to consider the options for mating the components. In
order to more fully understand the requirements of an efficient geometric and dimensional
relationship between a tractor mounting system and a front mounted mower, the author
66
examined a number of tractor mower combinations. These investigations indicated that a
significant number of modifications would have to be made to the MFM unit in order to
adapt it to front mounted operation. Additional problems were foreseen due to component
collision arising from the inherent differences in the height requirements of front mounted
and rear mounted mowers.
Having formulated initial ideas for solution of the issues identified and having
incorporated these into the model design, further discussions were held with MFM. The
author’s suggestions included the reduction in operational diameter of the conditioner unit
and the lowering of the rear hood. These changes would significantly lower the overall
height of the complete mower unit and would create vertical space in order to
accommodate more efficient positioning of gear boxes and drive-shafts; the extra room
would allow for less angular deviation in the drive from the tractor to the mower’s central
bevel gear box and also from this component to the side bevel gearbox. MFM was not in
favour of these modifications as the subcontractor- supplied conditioning unit is common
to all the models in the Malone range and thus accrues economy of scale benefits in
purchasing, servicing and spare parts stocking etc.
Figure 4.31 Side panels
MFM staff appreciated the height lowering necessity and suggested that the author
investigate how this could be achieved while retaining the existing conditioner unit. The
author carried out further design work on the model and modified the side panels (Figure
4.3) in order to lower the roof of the conditioner without compromising the minimum
67
clearance required for its efficient operation. If this clearance was exceeded, grass flow
would be impeded resulting in clogging and excess stress being imposed on the restrictor
plate. The extra stresses would impose un-designed for loads on the conditioner bearings
and the belt drive assemblies resulting in excessive noise, drop in performance and
premature failure.
4.2.3 Main Assembly

The author created a new assembly within the working directory and imported the
previously constrained and modified MFM mower. The previously constrained Feraboli
attachment system was inserted and temporarily positioned adjacent to the mower.
With any front mounted mower it is an important facet of design that the machine is
symmetrically mounted to the tractor for transport purposes and that equilibrium is
maintained about its pivot point for floating purposes. In order to symmetrically align the
two models in the left to right direction the author utilised common parametric modelling
techniques. The models were mated with coincident planes which had previously been
created along the centre lines of each and MFM staff agreed to this approach. The author
brought to their attention the fact that (due to the gearboxes and drive-shafts being
positioned on only one side of the mower) symmetrical positioning in this manner would
significantly unbalance the loading if the pivot point also lay in the same central plane. In
order to prevent this imbalance the author decided to position the pivot point offset from
the central plane. The resolution of these issues are illustrated in Figure 4.4 This attention
to detail was appreciated by the MFM staff and in order to facilitate the design process
they advised that rather than carry out complex calculations to determine the optimum
offset distance, the author should use the existing dimension as employed by Feraboli.
However the author decided to carry out a calculation exercise in order to accurately
determine the offset distance required.
68
Figure 4.32 Mower front view showing symmetrical position of Feraboli unit to mower and offset pivot point
4.2.4 Pivot point

After reviewing the original mower in Creo and examining it in the workshop it was
evident that the main structural member is a back bone of 80x80x8mm box section steel
running horizontally from side to side and from which the bed and gearboxes etc are
suspended (Figure 4.5).
Figure 4.33 Main structural

support member
Figure 4.34 Mower bed and spinal box section.
69
The box section runs parallel to the bed of the mower which in this particular model is
designed to lie at 8o to the horizontal in the front-rear direction (Figure 4.6). After
consultation with MFM, the conclusion was drawn that the attachment system should be
connected to this box section, as it is the strongest structural member and the pivot point
should be as close as possible to it. In the model the pivot point has therefore been
designed welded to the box section in a position which allows the mower assembly to be in
equilibrium.
The MFM engineer specified that the actual pivot point assembly be fabricated from 8mm
sheet steel. This specification presented a challenging design exercise for the author as he
had little experience in using the software for sheet-metal design. It was decided to
fabricate the assembly from five separate pieces, each involving individual features such as
cut outs, holes and bends. In particular, the side plates were required to be robust enough
to carry the loads imposed by the weight of the mower and also have cut outs large enough
to accommodate the swing of the machine as it balanced about the pivot point.
As the author had little experience in workshop sheet-metal techniques and was unsure of
bending capabilities and weld gap allowances, he decided to take further advice. In order
to be confident of the integrity of this particular design element, the author consulted with
the workshop fabricators to ensure that the component could be manufactured as designed.
70
Following their advice, modifications were made so that the assembly of the various steel
panels could be achieved accurately in the workshop. In particular, location tabs have been
added to the side plates and end plates which will interference fit into slots in the base in
order to facilitate assembly before welding, thus ensuring correct positioning of each
component holding the pivot pin (Figure 4.7).
Figure 4.35 assembly tabs and slots
Once each individual piece had been designed, an assembly was created with the base
piece constrained and the sides and ends inserted. At this stage it was assumed that the
pivot point assembly was finalised.
However, the MFM engineer was not completely satisfied with this design as it was
realised when the component was added to the assembly that there were problems with the
angular deviation of the cross-body drive shaft, due to the location of the main structural
box section to which the pivot point assembly was welded and on which the gearboxes
were mounted. To ensure the structural integrity of the design, the in-house engineer
required the pivot point assembly to be securely welded directly to the box section which
lay at 8o to the horizontal and parallel to the bed (Figure 4.8).
Figure 4.36 Pivot point assembly box section at 8o
71
After discussions of the options it was decided to reset the box section to 0 o as shown in
Figure 4.9. Accordingly the author re-designed the setup but it was then realised that this
change would introduce a negative effect on the drive train stresses at the side gearbox.
Figure 4.37 Pivot point assembly mated at box section at 0o
A solution was finally agreed upon - the system has now been designed with both the
mower bed and the box section lying at 4 o to the horizontal as shown in Figure 4.10. The
pivot pin assembly now required modification in order to achieve parallel mating surfaces
between the box section and the pivot point assembly sides which would allow a
satisfactory fillet weld to be carried out.
Figure 4.38 Pivot Point assembly mated to box section at 4o
The finalised design for this important component after incorporation of the agreed
modifications can be seen in Figure 4.11. The actual pivot pin could then be simply
modelled.
Figure 4.39 Final pivot point assembly design 72

4.2.5 Drive mechanisms
The author had now completed a design to physically attach the Feraboli assembly to the
MFM mower. However, other issues needed to be considered to ensure the integrity of the
design and that the functionality and operational efficiency of all of the dynamic
mechanisms in the complete machine assembly were not compromised.
The drive train to the mower bed required close design attention in order to minimise
angular deviation which would cause unnecessary stress on the shafts and universal joints
in the system.
To achieve this, the central gearbox was required to be positioned exactly on the centre
line of the mower (as the tractor PTO output is centrally located) and the side gearbox
located vertically above the bed where the drive would enter it. It became clear to the
author that the central gearbox mounting could be rigidly attached to the previously
designed pivot point assembly. If this could be achieved, the box section, pivot point
assembly and gear box mounting would constitute one unified fabrication of great strength
and rigidity thus benefiting the robust performance of each.
After receiving a hard copy annotated and dimensioned diagram of the gearbox from the
supplier the author modelled the external shell with output and input shafts (Figure 4.12).
Figure 4.40 Central gear box
As already discussed, the gearbox must preferably be positioned in the centre line of the
mower. The pivot point is not similarly located but is offset in order to ensure balancing of
the complete mower assembly. On account of this variation, the gearbox could not be
simply mounted vertically above the pivot point but brackets which would produce the
required offset would need to be designed. In order to assist this process, the author
sketched the side plates in 2D Autocad in order to investigate and determine the bend
angles and distances required (Figure 4.13).
73
Figure 4.41 2D views of central gear box mounting brackets.
Accordingly the author modelled a design for this component in Creo and added it to the
pivot point assembly as shown in (Figure 4.14).
Figure 4.42 Gear box mount initial design
The MFM engineer closely examined the design and advised that there was inadequate
clearance between the hood of the mower and the input drive shaft from the tractor.
Although there was not actual component collision, the distance between them was quite
small and he requested that the author revisit the design and modify it to increase the shaft
clearance. The author was able to accomplish this by extending the upper end of the side
plates as sketched in Figure 4.15 using AutoCad.
Figure 4.43 2D views of central gearbox final design
74
This final design was now modelled in Creo as shown in Figure 4.16. Three 8mm steel
plates are fabricated to form the complete component incorporating the dimensions and
offset angles determined from the previous development process. This sub-assembly was
inserted into the main mower assembly and the gearbox mounted in place.
Figure 4.44 Gear box mount in final position.
The model was examined by the MFM engineer who expressed his satisfaction with the
author’s designed solution which had overcome the problems encountered with gearbox
location.
75
4.2.6 Side mounted gear box
The output shaft of the side mounted bevel gearbox is required to be perpendicular (both in
the front to back direction and the side to side direction) to the bed of the mower at all
times. Any deviation will result in excessive stress on components, the over loading of
bearings and rapid wear of bevel teeth and lead to premature failure. Again the
80x80x8mm box section which forms the structural back bone provides a suitable location
for the rigid mounting of this component.
Having received a hard copy annotated and dimensioned diagram from the supplier the
author modelled the gearbox shell complete with input and output shafts. This shell was
inserted into the model and constrained do that it was correctly positioned as required. The
author could then model a robust mounting bracket to secure the gearbox to the box
section. The author wished to produce as rigid as connection as possible at this point and
the design is shown at Figure 4.17.
Figure 4.45 Initial design side mounted gear box bracket
It should be noted that the bracket is formed to wrap around the box section enabling a
maximum amount of contact for fillet welding. This component was inserted into the main
assembly and positioned using mating techniques. Investigation showed that this bracket
located the gearbox output shaft truly perpendicular to the mower bed in all directions.
However, in a subsequent meeting with the MFM engineer it transpired that the author had
been supplied with data of an older gear box design, the casing of which was
76
dimensionally different from the current model which is to be used the new mower. The
author was therefore obliged to revisit this particular task.
The new gear box casing required that it be mounted 26mm further towards the back of the
mower in order that the output shaft is perpendicular to the bed in the front-back direction.
The author redesigned the bracket to facilitate this (Figure 4.18).
Figure 4.46 Side gear box mounting bracket final design
The new component complete with correctly positioned mounting holes was incorporated
into the main assembly and the perpendicularity of the output shaft to the bed of the
mower confirmed.
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4.2.7 Baffle plate
The Malone mower body is higher at the back compared to the models produced by John
Deere and Claas and a baffle plate fixed to the underside of the hood must be incorporated
into the design in order to direct the flow of cut grass under the tractor. There were a
number of issues to be addressed during the design of this baffle plate such as:
 overall size of the plate

 angle of the plate relative to the hood
 rigidity of the plate
 fixing of the plate
The baffle plate size was restricted due to the positioning of the A-frame; it was important
that there would be no clash between the tractor and the baffle plate. Additionally, the
mounting position of the plate to the mower was restricted to direct bolting to the
underside of the hood. A number of folds were then needed to be incorporated into the
design of the plate in order to achieve a sufficient curvature to direct the grass downwards
and rearwards. The solution to this design problem was a very time consuming process that
involved various changes to the angles of the bends in the plate in order to optimise its
performance in use. The final design shown in Figure 4.19 involved six individual folding
operations to be carried out on the already laser cut plate.
Figure 4.47 Baffle plate
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4.2.8 Conditioning system
The conditioning system consists of two main components (Figure 4.20), the conditioner
unit and the conditioner hood.
Figure 4.48 Conditioning unit
The conditioner unit is made up of a number of tines mounted on to a rotating shaft and the
hood is simply an encircling plate which confines the
flow of grass and facilitates the bruising action of the
tines (Figure 4.21). The degree of conditioning can
be adjusted by rotation of the hood about the axis of
its lower edge.
Figure 4.49 End view of conditioner
The design required that the curvature of the hood would not under any conditions result in
clogging of the grass. Additionally this component was required to fit under the top cover
of the mower and incorporate a user-friendly system of adjustment. As MFM’s
manufacturing facilities obliged the fabrication of the hood by folding flat plate (Figure
4.22), the correct modelling of the bend angles to achieve the required parameters was
necessary. Additionally, the axis mounting brackets and edge strengthening plates required
design as did the hood positional locking system on the mower body (Figure 4.23).
4.2.9 Front gate hinge
Figure 4.50 Hood positional locking

Figure 4.51 Conditioning hood
In order for system
the operator to gain access for service and
79
maintenance to the bed of the mower the front gate must be lifted and locked in an open
position. The decrease in width of the front gate required design changes to the hinge
system (Figure 4.24).
Figure 4.52 Hinge system
4.2.10 Pulley safety guard

MFM wished to ensure that a high level of safety was incorporated into design. The
original design of the pulley guard was therefore revisited in order to ensure that it
provided the maximum level of protection without compromising efficient machine
operation. A number of designs were modelled and evaluated before the final solution was
chosen. The final design consists of a front and back cover as shown in Figure 4.25.
4.2.11 Specification change to 3m cutting bed

A late decision was made Figure
by MFM that asafety
4.53 Pulley 3m guard
cutting bed (Figure 4.26) would be used in
the purposed front mower. There were a number of reasons for this decision:
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 The wider model of cutting bed available was designed specifically for front
mower operation with the external pairs of cutting discs and ‘pots’ on each side
directing the cut grass inwards, thus creating a narrow swathe to avoid the tractor
wheels.
 The wider cutting width was considered to be an advantageous selling point for the
proposed new model.
 The wider cutting bed could be sourced from the manufacturer at a more
favourable cost due to economies of scale on the manufacturing side.
External pairs of
cutting discs and pots
Figure 4.54 3-metre cutting bed
This decision required an extensive redesign of how the bed of the mower would be
attached to the mower body. On the original mower, the cutting bed was secured in a ‘bed
tray’ which was then located in ‘bed runners’ fixed to the mower body. The author
intended to retain this method of fixing for the new bed.
It became obvious that the original mounting system would be inadequate for the
incorporation of the 3m bed. Not only was the new bed wider by 0.2m but it was also
deeper front to back by 0.075m.These dimensional differences could not be accommodated
by simple modifications to the original ‘bed tray’/ ‘bed runner’ design. In order to optimise
the ‘clean’ operation of the mower, it was required to maintain the original distance from
the edge of the cutting diameter to the edge of the sweep distance of the conditioner. Any
81
increase of this distance would result in the fall down of grass between the bed and the
conditioner and the machine would leave a trail of grass on the field.
The structure of the new bed had significant differences with regard to its mounting points
and when located in a lengthened ‘bed tray’, it was found through modelling that it was
positioned too far forward of the conditioner. Attempts to modify the ‘bed tray’ in order to
locate the new bed in the position required were unsuccessful, and it was judged that a
complete redesign of this component would be needed. However, MFM felt that the new
bed was structurally strong enough to not require the extra support provided by a ‘bed tray’
and suggested that other methods of mounting be investigated.
The author designed a mounting system as shown at Figure 4.27. The bed is supported by
a mounting plate bolted to the lower side and rear edges of each corner. This mounting
plate is fabricated along with a strengthening plate which lies flush with the top surface of
the bed. The complete assembly is located on the mower body by use of a mounting
bracket.
Mounting bracket
Mounting
plate/strengthening plate
fabrication
Mounting plate
Strengthening plate
Figure 4.55 Bed mounting configuration

The incorporation of a different cutting bed of longer width and depth required extensive
redesign or modification to many other components including:
82
 the main structural member
 the conditioner drive shaft
 the gear box bracket
 the side safety gate
 the tensioner bracket
 the safety guard bracket
4.2.12 Box section structural spine

The body of the mower is suspended from structural spine of 80x80x8mm box section
running from side to side across the machine. This now had to be extended in order that
the side mounted gearbox would remain vertically above the input to the new bed.
4.2.13 Conditioner drive shaft

Due to the extension of the mower bed, the conditioner shaft (Figure 4.28) was required to
be extended to suit. In order to accommodate the extra stresses caused by the additional
shaft overhang on the supporting bearing, the diameter was increased following
calculation.
Figure 4.56 Conditioner drive shaft
83
4.2.14 Tensioner bracket
The tensioner pulley mounting bracket was now required to be redesigned in order that the
jockey would align with the new position of the driven pulley. The author designed a new
tensioner bracket that can be seen in Figure 4.29.
Figure 4.57 Tensioner bracket
A location tab for the pulley guard assembly was also incorporated into the design.
4.2.15 Safety guard bracket

In order to satisfy and exceed health and safety requirements all safety guard mountings
were designed to be rigid and robust in order to withstand the operational vibrations and
stresses. This was achieved by designing a U-shaped bracket (Figure 4.30) that could
connect the pulley guard assembly to the main body of the mower.
Figure 4.58 Safety guard bracket
84
4.2.16 Side gate
The side gate is a safety feature which prevents the extreme cutting discs from coming into
contact with people or animals when the machine is operational. In the closed position they
add considerable width to the mower and are normally folded up for transportation. The
width extension prevented this operation from being completed with the original design of
side gate on the left hand side. The redesign involved modifying the front gate as shown in
Figure 4.31.
Figure 4.59 Side gate
4.2.17 Driveshaft guard

The vertical driveshaft transmits power from the side mounted gearbox to the bed of the
mower. A guard is required to prevent operator contact with the driveshaft and deflect
grass from coming into contact with the rotating shaft. The installation of the wider bed
which had a new location for the driven ‘pot’ and a larger ‘pot’ diameter required a
redesign of the existing guard and arrangement for its location as seen in Figure 4.32.
Figure 4.60 Driveshaft guard
85
4.2.18 Driveshaft guard location bracket
To locate the driveshaft guard on the left hand side a support bracket was designed as
shown in Figure 4.33
Figure 4.61 Driveshaft guard location bracket
86
4.2.19 Grass boards
With any front mounted mower it is required that the mown grass is directed into a central
swathe which will avoid being crushed by the tractor wheels. This is normally achieved by
the incorporation of a baffle plate mounted to the top of the conditioner hood and a grass
board attached to each side. These features combine to tunnel the mown grass into a
central swathe after the conditioning stage.
The top baffle plate directs the conditioned grass downwards and is usually fixed in
position while the grass boards taper the swathe inwards. MFM requested that the author
design grass boards for the new model and he was asked to produce preliminary ideas.
The author originally designed a new board as shown in Figure 4.34, which could be
bolted directly to the side panels of the conditioner hood. However, he was unhappy with
the functionality of the component and suggested that the machine could be greatly
improved by the addition of adjustable grass boards. MFM agreed, considering that this
modification would appeal to many prospective customers.
Figure 4.62 Initial grassboard design
The author produced a second design which was an improvement both structurally and
aesthetically and could be hinged to the side plates of the conditioner hood. A number of
hinge designs were proposed. For example, a design was modelled which combined two
short steel tubes welded to the edge of a grass board with a loose fitting full length pin.
When used in conjunction with mounting brackets bolted to the edge of the side panel, this
system formed a loose pin hinge.
87
On the suggestion of MFM, this hinge system was changed in order to leave it easier to be
manufactured while retaining the basic principle of operation. The full length pin is now
welded to the edge of the grass board and pivots directly on the on the side panel mounted
brackets (Figure 4.35).
Figure 4.63 Final design of grassboard
Locking of the grassboard in a chosen position will be achieved quite simply by use of the
component shown in Figure 4.36. An angle piece is bolted to the top of the hood and
slotted to coincide with a slot in the top of the grass board. Locking of the board in
position can be accomplished by tightening a large wing nut with bolt and washer.
Figure 4.64 Grass board adjsuters
88
4.3 Design calculations
4.3.1 To find centre of gravity of mower
Figure 4.65 Free body diagram
Loads are as following:

P1= 230N
P2=2697.75N
P3=2697.75N
P4=130N
P5=265N
To locate the centre of gravity
AntiClockwise Moments=Clockwise Moments
Right side
(2697.75N) x (0.75m-X)+(265N)(1.236m-X)+(130N) x (1.5m-X)
=) 2023.31N∙m-2697.75N x X + 327.54N∙m- 265N x X +195N∙m-130NxX
Left side
(230N)(X) + (2697.75N)x(X+0.75m)
=) 230N x X+2023.31N∙m+22697.75NX
=) 2023.31N∙m+2927.75N x X
AntiClockwise Moments=Clockwise Moments
2023.31N∙m+2927.75N x X=2545.88N∙m-3092.75N x X
522.57N∙m=6020.5N x X
X=0.087m
The location of the centre of gravity of the mower is 0.087 metres to the right side of
centre.
89
4.3.2 To calculate shock loading
In order to calculate maximum impact loading on the pivot point and pin of the machine,
the author decided to carry out research with a number of local agricultural contractors in
order to discover if there was common agreement on what particular operational situations
gave rise to maximum shock loading. It was concluded that the most common perceived
maximum shock occurred when implement and tractor would traverse a standard traffic
calming road ramp while travelling at the mower manufacturer’s maximum recommended
road speed of 30 kmph. Apparently this seemingly unlikely event does occur, particularly
when a tired operator is transporting the machine by road following possibly a 16 hour
continuous operational shift. A number of local road ramps were measured and the average
profile identified (Figure 4.38).
Figure 4.66 Road Ramp
It was decided to calculate the multiple of the static load which would result in the vertical
plane due to the crossing of the ramp at speed. This was accomplished using the following
calculations:
Assuming a ramp of
H= .150m
W= .800m
.150m
Average incline θ
0.15 m
tanθ=
.400 m .400m
ο
θ=20.55
90
Assuming tractor travelling at 30 kmph
1000 m
v=30 kmph x =8.3 m/s
3600 s
resolving horizontally v = 8.3 cos 20.55 = 7.77 m/s
resolving vertically v = 8.3 sin 20.55 = 2.91m/s
time to travel 0.400m at 7.77m/s
S
t=
v
time¿ 0.400m
7.77m/s
time=0.051480 s
For vertical movement
u= 0 m/s
v= 2.91m/s
s = 0.15m
t = 0.05148
By equation of motion:
v=u+at
2.91 m/s=0 m/s +0.05148 s x a
2.91 m/s
=a
0.05148 s
2
56.52 m/s =a
Acceleration dues to gravity = 9.81m/s2
Multiple of static loading on pin due to shock impact= 56.527/9.81= 5.76
91
4.3.3 To specify bolts for alternative design option.(attachment of pivot point)
An alternative method of attaching the pivot point to the mower body was identified by the
author. The bottom plate of the pivot point assembly could be bolted to the top of the
mower body. The number, size and grade of bolts was ascertained.
Total weight of mower body= 550kg
Load generated = 550kg x 9.81m/s2= 5.3955 kN
Maximum impact load (Section 4.3.2) 5.3955 x 5 .76= 31.02 kN
Assuming grade 8.8 10mm steel bolts Table 8.4
AE
kb=
L
Area = π x ¿ ¿
2
π x ( 0.01 )
Area = π x ¿ ¿
4
A= 7.8539 x 10-5m2
Young’s modulus of steel to be 210 GPa
kb = Stiffness of the bolt
−5 9
7.8539 x 10 x 210 x 1 0
kb= −3
16 x 1 0
kb = 1030.82 x 106 N/m
Assuming special case
 Same thickness of material

 Same type of material
Km=Member stiffness
πx Ed
km=
l+ 0.5 d
2 ln (5 )
l+ 2.5 d
92
π x 210 x 1 09 x 0.01
km= −3
16 x 1 0 +(0.5 x 0.01)
2 ln (5 −3
)
16 x 1 0 +(2.5 x 0.01)
6
6597.34 x 10
km=
1.8807
km= 3507.917 x 1 06 N/m
Ratio of stiffness of members and stiffness of bolts
kb
Cb=
kb+ km
6
1030.82 x 10
Cb=
1030.82 x 10 6 +3507.91 x 10 6
Cb = 0.2271
To find out the number of bolts required
CxP
σa=
2 At N
Fi
Sut−
At
Sa=
Sut
1+
Se
Se= ka kb kc kd ke kf Se’
Se’= [ 0.566 – 9.68x105 x 830] x 830
Se’= 463.11 MPa
1
Se= x1
2.2
Se= 154.37 MPa
Fi = 0.75 Fp
Fp = At x Sp
93
Fp= 58 x 1 0−6x 600 x106
Fp = 34.8kN
Fi = 0.75 x 34.8x1 03
Fi= 26.1 kN
Sut = 830 MPa Table 8-4
16.53 x 1 03
830 x 1 06−
58 x 1 0−6
Sa=
830 x 1 06
1+ 6
154.37 x 1 0
Sa= 59.59 MPa
Assuming factor of safety of 2
Sa
n¿
σa
Sa
σa=
n
6
59.59 x 1 0
σa=
2
σa = 22.310 MPa
CxP
a=
2 At N
CP
N=
2 At
0.2271 x 31.02 x 1 03
N=
2 x 58 x 10−6 x 29.790 x 1 06
N= 2.1
Figure 4.67 Bolts layout
N=3
Total bolts required = 8 bolts
94
The bolts required in order to satisfy the maximum impact load have been calculated
at 3 number/side, of diameter 10mm grade 8.8.
4.3.4 Conditioner shaft calculation

Power = (T 1 –T2) v
T 1 μα
¿e
T2
t1
T 2= μα
e
T 2 ¿ T 1 e−μα
Sub in for T2
Power = (T1 – T1 e− μα) v
Rpm = V/( πx d ¿
V= rpm x ( πx d ¿
V= 850rpm x ( π x 237 x 10−3 ¿
V= 10.54 m/s
Output power
Rated output power(Gear box Spec sheet) = 19.3 da N∙m
` Rated output power = 193 N∙m
Output speed = 1000 rpm x 2 π /60s
Output speed = 104.71 rad/s
Power=Torgue x Angular velocity
20210.9 w = 193 x 104.7
Power= 20.2 kW
95
Power = (T1 – T1 e− μα) v
20.2 x10 3 = ( T1- T1 x10-5 x 3.14)x10.5
1924.8 = T1 – 0.4546 T1
1924.8 = 0.5 T1
T1= 3564.5 N
For conditioner pulley
T1= 3564.5 N
T 1 μσ
=e
T2
T1
T 2= μσ
e
3564.5
T2= 0.25 x 3.14
e
3564.5
T2=
2.192
T2= 1625.84N
Diagram of forces on pulley

3664.5N
53o
1625.84N
57o
F1X = 3564.5 x cos 53 = 2145.17 N
F1Y = 3564.5 x sin 53 = 2846.74 N
F2X = 1625.84 x cos 57= 885.50 N
96
F2Y = 1625.84 x sin 57 = 1363.54 N
EFX= 3030.67 N
EFY = 4210 .28 N
Forces in the y- direction
Figure 4.68 Shear force and bending moment diagrams in y-direction
97
Forces in the x direction
Figure 4.69 Shear force and bending moment diagrams in x-direction
Max bending moment
Mb=√ ¿ ¿
98
Mb=1255.4 N ∙ m
F2X
F1Y F2Y
F1X
∑ Mo=F 1 y x d −F 2 y x d+ F 1 x d−F 2 x d
= (2846.74 – 1363.54 + 2145.17 – 885.5) x 118x10-3
= (2742.87 x 118 x 10-3)
= 323 .65 N ∙ m
Ta = 323.65 N ∙ m
Applied torque steady with no amplitude Steady torque
To find minimum diameter under static loading
d=¿
Assuming BS817M40T steel
Tensile strength = 850 N/mm2
Yield strength = 680 N/mm2
Assuming a factor of safety of 3
d=¿
d=0.03876 m
99
d=38.76 mm
d=39 mm
Minimum diameter under static loading is 39 mm.
Under fatigue loading
32 x n
d= x [ ¿¿¿
π
Ka= 0.70 Figure 7-13
kb=
{1.1891.0x 39d <8 mmd >8 mm
−0.097
kb=
{1.1891.0d d< 8d>mm8 mm
−0.097
kb=0.8313
kc=¿ 1 Assuming 50% reliability
kd = {0.5350<
1.0 T < 350
T <500
kd =1
ke=1
kf =¿1
Se= Ka x kb x kc x kd x ke x kf Se '
'
S e =0.5 Sut
S e ' =0.5 850 x 106
' 6
S e =425 x 10
Se=0.7 x 0.8313 x 1 x 1 x 1 x 1 x 425 x 10 6
Se=247.32 MPa
Assuming constant speed of belt rotation so there is no torque amplitude

100
τa=0
Assuming steady torque of 323.65 N ∙ m
1255.4 N ∙m+(−1255.4 N ∙ m)
Mm=
2
Mm=0
1255.4 N ∙ m−(−1255.4 N ∙ m)
Ma=
2
Ma=1255.4 N ∙m
32 x 3
d= x ¿¿¿
π
d=0.0538 m
d=54 mm
Minimum diameter under fatigue loading is 54 mm.
101
4.3.5 Pivot pin static
Figure 4.70 Schematic of pivot pin
Figure 4.71 Shear force and bending moment diagrams under static loading
102
Transverse shear
VQ
τ=
IT
π d4
I=
64
π (40 mm)4
I=
64
I = 125663.71mm4
3
d
Q=
12
(40 mm)3
Q=
12
3
Q=5333.3 mm
2697.79 N x 5333.3 mm3

τ= 4
125663.71 m m x 40 mm
τ =2.862 MPa
To calculate the factor of safety of the pivot pin.
Assuming BS7080M40 hardened and tempered steel is being used (Table A.16)
Yield strength= 525 MPa
Sy
τmax =
2n
Sy
2 n=
τmax
525 MPa
2 n=
2.862 MPa
2 n=150.24
n=91.71
103
A factor of safety of 91.71 under static loading hand calculations
4.3.6 Pivot pin ANSYS Analysis

Static Loading
In order to calculate the factor of safety of the pin and to ensure

that it was fit for purpose the author carried out an ANSYS
analysis on the pivot pin. As the pressure is not distributed over
the pin evenly, the contact area was reduced to 120o to
compensate. As symmetry was present, pressure is applied over Figure 4.72Pressure
distribution on a pin
60o. At static loading, a pressure of 0.73471MPa was found to be
applied to the pin under static loading.
P=F/A
2697.75
P=
( 17.32 x 212)
P=0.73471 MPa
Figure 4.73 Max stress and deflection Figure 4.74 Max shear stress under static loading
The stress intensity (figure 4.45) was then plotted and τmax of 21.21MPa was read from
the plot. This was then used to determine a factor of safety using BS708M40 hardened and
tempered steel (Table A-16) with a yield strength of 525 MPa. Using the following
equation below a factor of safety of 12.37 under static loading was found.
Sy
2 n=
τmax
525 MPa
2 n=
21.21 MPa
2 n=24.75
104
n=12.37
4.3.7 Pivot pin impact load
Figure 4.75 Shear force and bending moment diagrams under impact loading
105
3
15538.54 N x 5333.3mm
τ=
125663.71 mm4 x 40 mm
τ =16.48 MPa
15538.54 x 5333.3mm 3
τ=
125663.71 m m4 x 40 mm
15538.54 x 5333.3mm 3
τ=
125663.71 m m4 x 40 mm
τ =16.48 MPa
To calculate the factor of safety of the pivot pin under impact loading using hand
calculations.
Sy
τmax =
2n
Sy
2 n=
τmax
525 x 1 06
2 n=
16.48 x 1 06
2 n=31.85
n=15.92 Factor of safety hand calculations for impact loading on pivot pin.
106
4.3.8 Impact Loading Analysis
P=F/A
2697.5 N x 5.76
P=
( 17.32mm x 212 mm)
P=4.2315 MPa
At impact loading, a pressure of 4.2315MPa was applied to the pin.
Figure 4.76 Max stress and max deflection Figure 4.77 Max shear stress under impact loading
The stress intensity (Figure 4.48) was then plotted and

τmax of 122.19 MPa was read from the plot. This was the used to determine a factor of
safety using BS7080M40 cold drawn steel (Table A-16) with a yield strength of 525 MPa.
Using the following equation below a factor of safety of 2.14 under impact loading was
found.
Sy
2 n=
τmax
Sy
2 n=
τmax
525 MPa
2 n=
122.19 MPa
2 n=4.29
n=2.14
107
4.3.9 Pivot point Static load on 36mm pin
Transverse shear
VQ
τ=
IT
π d4
I=
64
4
π (36 mm)
I=
64
I = 82447.96mm4
d3
Q=
12
3
(36 mm)
Q=
12
3
Q=3888 mm
Static loading
3
2697.79 N x 3888 mm
τ= 4
82447.96 mm x 36 mm
τ =3.53 MPa
To calculate the factor of safety of the 36mm pivot pin under static loading.
Sy
τmax =
2n
Sy
2 n=
τmax
525 MPa
2 n=
3.5338 MPa
2 n=148.56
n=74.28
108
A factor of safety of 74.28 under static loading using hand calculations
4.3.10 Static loading ANSYS analysis on 36mm

The author decided to investigate the factor of safety provided by a pin of smaller
diameter. A pin of 36mm diameter was analysed and at static loading a pressure of
0.73471MPa was applied to the pin.
P=F/A
2697.5 N
P=
( 15.59mm x 212mm)
P=0.8161 MPa
Figure 4.79 Max shear stress under impact loading
Figure 4.78 Max stress and max deflection
The stress intensity (figure 4.51) was then plotted and τmax of 28.73MPa was read from
the plot. This was then used to determine a factor of safety using BS7080M40 cold drawn
steel (Table A-16) with a yield strength of 525 MPa. Using the equation below a factor of
safety of 9.13 under static loading was found.
Sy
n=
τmax
Sy
2 n=
τmax
525 MPa
2 n=
28.7373 MPa
2 n=18.26
n=9.13
109
4.3.11 Impact loading on 36mm pin
15538.64 N x 3888 mm3
τ= 4
82447.96 m m x 36 mm
τ =20.35 MPa
To calculate the factor of safety of the pivot pin.
Sy
τmax =
2n
Sy
2 n=
τmax
525 MPa
2 n=
20.35 MPa
2 n=25.79
n=12.89
A factor of safety of 12.89 under impact loading using hand calculations.
110
4.3.12 Impact Loading ANSYS analysis
P=F/A
2697.5 N x 5.76
P=
( 15.59mm x 212mm)
P=4.701 MPa
At impact loading, a pressure of 4.701MPa was applied to the pin.
Figure 4.81 Max stress and max deflection
Figure 4.80 Max shear stress under impact loading
The stress intensity (figure 4.52) was then plotted and τmax of 165.536 MPa was read of
the plot. This was the used to determine a factor of safety using BS7080M40 hardened and
tempered steel (Table A-16) with a yield strength of 525 MPa. Using the equation below a
factor of safety of 1.5 under impact loading was found.
Sy
2 n=
τmax
Sy
2 n=
τmax
525 MPa
2 n=
165.536 MPa
2 n=3.17
n=1.585
111
4.3.13 ANSYS analysis on pivot point
The author identified the pivot point as a stress ‘hotspot’ of the mower. In order to verify
the structural integrity of the design of the pivot point, it was analysed using ANSYS. The
author decided to apply pressure to the bushing of the pivot point and from this the factor
of safety was determined. As pressure is not distributed over the bushing evenly, the
contact area was reduced to 120o to compensate. As symmetry was present, it must be
applied so this meant that the pressure is applied to 60 o. In order to calculate the pressure
that was applied to the pivot point in ANSYS the author completed the following
calculations:
F
P=
A
Weight of mower body= 550kg
Force generated= 5395.5N
Because of symmetry the load was half
A= 17.32 x 70 = 1212.4mm2
5395.5 N
P=F/A 2
7343.68m m
P= 1.11256 MPa
Figure 4.82 Max stress and max deflection Figure 4.83 Local hotspot of Max stress
The Max stress smax (figure 4.55) was then plotted and smax of 15.0323 MPa was read
from the local hotspot of max stress (figure 4.54). This was the used to determine a factor
112
of safety using Optim 500 steel with yield strength of 500 Mpa. Using the equation below
a factor of safety of 33.2 under static loading was found.
Syt
n=
σmax
500 MPa
n=
15.03 MPa
n=33.26
To verify results static loading
113
F
σo=
( w−d ) t
2697.75
σo=
( 94−60 ) x 10
σo=7.93 MPa
Kt= 3 for a circle
σmax
Kt =
σo
σmax
Kt =
σo
Kt x σo=σ max
Kt x σo=σ max
3 x 7.93 = 23.80MPa
Syt
n=
σmax
500 MPa
n=
23.80 MPa
n=21
ANSYS−Theortical
Percentage difference= x 100
ANSYS
33.2−21
33.2
Percentage difference= 36.74%
This would be deemed high percentage difference and this will be discussed in greater
detail in the results.
Impact loading
114
F
P=
A
( 1348.875) x 5.76
P=
1212.4
P= 6.4083MPa to be applied
At impact loading, a pressure of 6.4083 MPa was applied to the bushing.
Figure 4.84 Max stress and max deflection Figure 4.85 Figure 4.86 Local hotspot of Max stress
The Max stress smax (figure 4.57) was then plotted and smax of 15.0323 MPa was read
from the local hotspot of max stress (figure 4.56). This was then used to determine a factor
of safety using Optim 500 steel with yield strength of 500 MPa. Using the equation below
a factor of safety of 5.86 under static loading was found.
Syt
n=
σmax
500 MPa
n=
85.304 MPa
n=5.86
To verify results impact loading
115
F
σo=
( w−d ) t
15539.04
σo=
( 94−60 ) x 10
σo=45.70 MPa
Kt= 3 for a circle
σmax
Kt =
σo
σmax
Kt =
σo
Kt x σo=σ max
Kt x σo=σ max
3 x 45.70 = 137.10MPa
Syt
n=
σmax
500 MPa
n=
137.10 MPa
n=3.64
ANSYS−Theortical
ANSYS
5.86−3.64
5.86
Percentage difference= 37.88%
This would be deemed high percentage difference and this will be discussed in greater
detail in the results.
116
4.4 Manufacturing
4.4.1 Production
MFM offer a range of products such as log splitters, post drivers, side mounted mowers
and self-loading wagons. Due to the limited size of the manufacturing facility, the firm’s
preferred method of working is to produce batch quantities of particular items in order to
satisfy expected seasonal demand.
For the larger products such as trail mowers and self-loading wagons the workshop is
organised basically on a process layout in which particular manufacturing operations are
grouped together in dedicated booths or work areas. Parts can be transferred from work
booth to work booth for different processes according to a preset sequence (Figure 4.59).
The various fabricated parts are delivered to a sub-assembly area where the mating
components are assembled into manageable sub-assemblies. They are then transferred to a
spray booth before delivery to a final assembly area in which the machine completed.
Painting Final assembly Testing
Sub-assembly
Fabrication
Welding
Folding
Research &
Laser Cutting
Development
Figure 4.87 Process layout

117
Although many of the MFM workshop staff have particular highly developed individual
engineering skills, they work together as a team. For example, two experienced welders
carry out all of the welding operations in a dedicated welding booth. However, if they were
restricted to welding operations, log-jams could occur in another fabrication process in a
different work area. As the goal is the turnout of a complete machine in as short a time as
possible, these operatives can provide assistance as needed throughout the workshop. This
practice is universally employed throughout the manufacturing facility, without strict role
demarcation. A further benefit of this teamwork culture is that occasions of operative
absence (for example through illness) do not cause major disruption to production output.
4.4.2 Research & Development

Research and development at MFM is carried out by an experienced mechanical engineer
in conjunction with management. The design facilities consist of three high-specification
workstations utilising 3-D engineering software including Creo Parametric and AutoCad.
Modifications and upgrades to existing products are formulated in the light of customer
feedback and research is carried out into the development of new and innovative products.
4.4.3 Metal cutting

In-house laser cutting of sheet-metal components plays a
pivotal role in the economic manufacture of all of MFM’s
products. The employment of Creo Parametric software
facilitates the efficient production and delivery of
accurate cutting data to this process, as the program has
an integral function dedicated to sheet-metal design.
Output from Creo can be exported directly to Wicam Figure 4.88 Plasma cutter
software which is utilised by the plasma cutter (Figure

4.60) to cut the designed profiles.
There are a number of components which will be cut from stock

using the in-house bandsaw (Figure 4.61).
Figure 4.89 Bandsaw
118
4.4.4 Press brake
Almost all of the sheet-metal components of the mower
have bends incorporated either as a functional feature of the
design or to provide rigidity or strength. In fact, particular
sections are required to be folded with multiple angles, for
example the conditioner baffle plate. These operations are
facilitated in the MFM workshop by a substantial hydraulic
press brake (Figure 4.62). In the working drawings the
author specified the particular V-blocks (Figure 4.63) which
would be required to be utilised in order to achieve the Figure 4.90 Press brake
particular folds for particular section thicknesses as

illustrated below:
 V22: 1,2,3 & 4 mm
 V35: 5mm
 V50: 6&8mm
 V80: 10 & 12mm
 V100: 15 & 20mm Figure 4.91 V-blocks
4.4.5 Tube bender

Among other metal forming processes which will be employed in the manufacture of the
mower are tube bending operations. For example, the standoff rail (Figure 4.65) which
surrounds the mower body will be shaped using the powerful MFM hydraulic bender
(Figure 4.64).
119
Figure 4.92 Side gate 4.4.6
Figure 4.93 Tube bender Welding process
Following laser cutting and bending, fabrication of
individual metal sections into sub assemblies can take place using welding processes. The
predominant process at MFM uses MIG welding technology. The staff employ the use of
dedicated fixtures and jigs in order to accurately locate components relative to each other
before welding in position. This facilitates the accurate, speedy and cost effective
construction of sub-assemblies. An example of such a jig, used to locate the tine holding
brackets of the conditioner unit (Figure 4.66), is illustrated in Figure 4.67.
Figure 4.95 Jig
Figure 4.94 Conditioner shaft
4.4.7 Painting
The fabricated sub-assemblies are now transferred to the preparation area of the paint
shop. The fabrications are thoroughly degreased and cleaned. They are then suspended
from an over head rail (Figure 4.69) which is used to move the components through the
different spraying booths in the paint shop. All the steel is etch-primed and then undercoat
is applied and allowed to cure before spraying of the two final coloured finishing coats
(Figure 4.68). The painted components pass into a drying oven (Figure 4.70) for curing.
120
Figure 4.96 Priming booth
Figure 4.98 Spraying booth Figure 4.97 Curing booth
Once the final layers of paint have fully cured, they are
transported out of the paint shop using the over head
rail. (Figure 4.71)
Figure 4.99 Stacking for assembly
4.4.8 Final assembly

At this stage the final assembly of the machine is carried out. This area of the workshop is
relatively large and accommodates all of the finished components for a complete mower.
A team of two experienced fitters carry out the task in the most efficient sequence which
has been identified, usually by trial and error with the first few models. The area is
equipped with all the necessary hand tools and small workshop equipment such as
pneumatic impact wrenches and trolley jacks. An overhead gantry and electrically
121
powered hoist is available for the slinging and positioning of heavy components such as
the cutting bed and conditioner unit (Figure 4.72).
Figure 4.100 Assembly of the conditioning unit
4.4.9 Final testing

Before the mower is released onto the market, it must be thoroughly tested in order to
avoid embarrassing and possibly expensive problems arising in commercial use. It is
vitally important that a new entrant into the agricultural implement sector immediately
gains a reputation for both functional efficiency and robustness. If a new mower was beset
with teething problems, its future economic success could be threatened. Furthermore, the
reputation of MFM could be damaged, affecting other products in the company’s range.
Pilot trials of the machine include field testing by the company, after which any
modifications judged necessary to the design or manufacture are carried out. When it is
considered that any shortcomings have been addressed, the machine is normally released
to a local agricultural contractor for a period of trialling. This will involve extensive and
continuous operation of the mower in all sorts of ground and crop conditions, possibly
under the control of a less than mechanically sympathetic operator. During this exercise
the performance of the machine is closely monitored by MFM and any issues identified are
addressed before commercial release.
5 Health and safety
5.1 Introduction to health and safety

Farm safety is a very important issue in modern day Ireland. The Health and Safety
Authority (HSA) [18] report that tractors and machinery are the main causes of farm
accidents in the country. Deaths are caused by crushing by or between machines and
122
entanglement in PTO shafts. Machinery manufacturers, operators, and owners are required
to ensure that machinery is safe to use at all times. According to the HSA, a number of
basic safety measures should be addressed by manufacturers and operators including:
 All safety guards/safety devices fitted and operational

 PTO shafts fully shielded with non-rotating and constrained guards
 All hydraulic hoses and fittings leak free and in good repair
 All machinery defects identified and corrected
 Regular inspection and maintenance carried out and recorded
5.2 Safety in the workshop

All activity in the MFM workshop is subject to the provisions of The Safety, Health and
Welfare at Work Act (2005) [18] which apply to all places of work. Basically the
employer is required to provide a safe environment for all the workers and to ensure that
manufacturing processes are completed incorporating safety practices as far as reasonably
practicable. The employees are required to look after their own safety and those around
them and to cooperate with the employer in all issues relating to safety. The Safety, Health
and Welfare at Work (General Application) Regulations (2007) [18] update a number of
existing regulations and implement the EU Amended Use of Work Equipment Directive.
An engineering workshop is a dangerous environment with many hazards having potential

for severe harm. Each individual workshop activity requires a hazard identification
exercise to be carried out and a risk assessment completed. The risk assessment should
identify the particular hazard, identify those at risk, quantify the probability and severity of
harm possible from the risk and specify control measures to reduce or nullify the risk.
Additionally each risk assessment is required to be updated if for any reason the working
situation changes, for example due to new machinery, young employees, non-English
speaking employees or different methods of working.
5.3 Safety measures incorporated into the front mounted mower

Machine operational safety was paramount throughout the project. A mower is inherently a
high risk machine due to the extreme cutting speeds involved and all moving parts must be
robustly guarded to prevent contact. Areas requiring attention comprise:
123
 the PTO shaft from tractor to mower and horizontal and vertical mower shafts
 the conditioner pulleys and belt systems
 the cutting discs/bed
 stones/debris ejected from the machine
The safety measures incorporated are illustrated below:
PTO safety covers
Side gate
Pulley system safety

cover
Standoff rail
Driveshaft cover
Front gate
Protective skirt
Figure 5.101 Safety components of Malone front mower
Side gate: The side gates and stand-off rail play a pivotal role in the safety of the machine
when cutting as they provide a sufficient clearance distance to prevent contact with the
cutting blades.
Front gate: The front gate offers protection from the rotating blades and hinders the
ejection of stones, debris and foreign objects upwards.
Protective skirt: The protective skirt offers shield like protection that hinders the ejection
of stones, debris and foreign objects from the front.
Driveshaft cover: The driveshaft cover provides protection from the spinning driveshaft.
It also prevents entanglement of grass around the shaft which can lead to overheating of
bearings and choking of the machine.
124
Pulley system safety cover: This provides protection from the rotating pulleys and drive
belts which transfer the drive to the conditioner.
PTO shaft covers: The PTO shafts must be fully enclosed in robust and vividly coloured
guards along their individual lengths. The guards must be restrained from rotation by
suitable chains which can be quickly and easily linked to fixed positions on the machine.
Baffle plate: The baffle plate at the rear of the mower offers a degree of protection from
foreign matter being ejected from the conditioner.
5.3.1 Other safety measures considered

The incorporation of safety measures to counteract other hazards which arise in the use of
mowers was considered, but none were deemed practical to implement. The issues
examined included:
 An operator becoming trapped or crushed while moving the mower between the
work and transport positions.
 An operator becoming crushed below a raised machine while replacing blades or

carrying out other maintenance work.
 An operator or others being struck by objects or debris ejected from the machine.
6. Results
Stress analysis has been carried out on a number of load bearing components in order to
verify their operational integrity. Where required such components have been modified
redesigned or re-specified in order to achieve the required factor of safety.
125
The tables below display the factors of safety calculated for the pin and pivot point under
both static and impact load. The calculations were completed both by hand and ANSYS
analysis. The tables also illustrate the percentage differences between the resulting figures
obtained. Examination of the figures reveals a high percentage divergence. This can be
attributed to the fact that the ANSYS program found the maximum value of τmax and
smax on each component, whereas in hand calculations the average value is ascertained.
Table 2 Factor of safety calculation results for pivot pin
The author specified a pivot pin of 40mm diameter BS708M40 steel
Table 3 Factor of safety calculation results for pivot point
Due to the design changes the author has completed a calculation on the required diameter
of the short driveshaft needed to power the conditioner unit. A diameter of 54mm was
calculated under fatigue loading. The author also investigated an alternative option for
attaching the pivot point to the mower body using bolted connections rather than welding
and specified the diameter, number and grade recommended.
6 Discussion
The acid test to the success of the project is the judgement of the manufacturing sponsor
MFM. The company expressed their satisfaction with the final design and felt ready to
advance to the manufacture of a full size and operational prototype. Unfortunately market
126
forces precluded prototype manufacture at this immediate juncture. The design work
finished in early March 2014, just as the seasonal surge of orders for the firm’s existing
forage products were being received. The workshop capacity was now required to be fully
dedicated to the manufacture of the current models of mower and forage wagon in order to
fulfil confirmed orders for which deposits had been secured and delivery times agreed. It is
the intention of the company to revisit the project in September 2014 with manufacture of
a working prototype.
Initial problems arose due to incompatibility of design software between Feraboli, MFM
and the author. These software conflicts resulted in the loss of functionality of a number of
the software features in the original models and the reconstitution of planes, mates and
assemblies was required. A further drawback was the author’s lack of experience in sheet-
metal design using Creo software and his almost total lack of knowledge of fabrication
methods and techniques utilised with this material.
Many design problems arose during the development of the model including:
 The attachment of the pivot point to the mower body to allow for the utmost
structural integrity for the design.
 The transmission of power from the tractor through to the gearbox and on to the
bed of the mower. As PTO shafts are to be maintained as straight as possible at all
times to minimise the stress, this issue required close attention.
 The location of the gearboxes was critical in order to minimise stress on the drive
train.
 The bed was required to be angled at 4o to the horizontal in order to reduce stress
on the universal joints. This figure was only identified after much trial and error
modelling in order to discover the optimum position.
 The major problems encountered in the design phase resulted from late alterations
to the specification of a major component (the cutting bed) which was received
from an external supplier. This re-specification at such a late stage in the product
development was not easily accommodated within in the model already produced,
and required a complete re-design of many components such as conditioner such as
side gate, pulley safety cover and tensioner adjuster.
127
Discussions with MFM, including valuable insights gained from speaking to workshop
operatives were of immense benefit to the design process. For example, the author was
unsure of the limitations of the press brake operations in sheet-metal folding and its ability
to complete folds in proximity to each other. A number of components required such
processes. For example the fabrication of the conditioner hood required folding of sheet-
metal plate into an approximately circular profile by applying a sequence of folding
operations to the sheet steel. Similarly, the welding staff were able to provide advice on
component design which would facilitate sufficient access to internal angles and corners in
order to achieve high quality and structurally strong welds. Assembly staff also imparted
valuable assistance regarding tolerances required for ease of assembly without
compromising machine operation.
In particular situations some components may be over-engineered, but have been so

specified at the request of MFM as judged to be currently the most cost-effective solution
to the engineering problem posed due to economies of scale in purchasing. For example
the use of 8mm plate in certain location may not have been justified by structural
requirement but as purchased by the firm in bulk its use was more financially economical
than lighter sheet. Due to the time constraints of the project the author did not have time to
investigate further into using the most cost effective available materials.
128
7 Conclusions/Recommendations
The most obvious recommendation that the author has for this project is the manufacture a
prototype. The author has several suggestions for
the design and future development of the front
mounted mower, such as a reduction in the
diameter of the conditioner unit. A reduction in
diameter would allow the back hood of the mower
to be reduced in height dramatically. This then
would have positive effects on the mower as it
would reduce the misalignment of the PTO shafts
that transmit power from the tractor to the bed of the
mower and therefore reduce stress on the shafts.
The author would also suggest adjusting the lifting height of the mower. The current
mower has a lift of approx 350mm which is just short of what is required to allow it to
clear grass lying in a swathe; the author would suggest alterations to the lifting system to
allow for a 450mm lift that would see mower clear these swathes. A cab operated
hydraulic gate lifting system would allow the operator to lower and raise the side gates
without having to leave the cab of the tractor. This could be marketed as an extra to the
basic machine and may become a valuable selling point.
The aim of this project was to use the

knowledge and skills that the author had
gained and developed over the past four
years at college and apply them to a real life
engineering development scenario. This
aim has been admirable achieved and the
author is extremely pleased with the
outcomes attained through his involvement
with the project. The challenge of designing
an engineering component in an industrial
environment has been enormous and the learning curve has been very steep. The author
has fully enjoyed the process.
129
Project Plan
130
References
[1] Malone Farm Machinery, “Malone Farm Machinery,” Malone Farm Machinery,
[Online]. Available: http://www.malonefm.com/about-malone-fm.html. [Accessed
13 October 2013].
[2] Feraboli, “Feraboli Agricultural Technologies,” Feraboli, [Online]. Available:

http://www.feraboli.com/en/prodotti/falciacondizionatrici_frontali_fr.php.
[Accessed 13 October 2013].
[3] Irish Patents Office, “Irish Patents Office,” Irish Patents Office, [Online]. Available:
http://www.patentsoffice.ie/en/patents.aspx. [Accessed 10 October 2013].
[4] Irish exportes association, Intelluctual Property Managment: A Guide For Exportes,
Dublin: Irish Exportes Association, 2004.
[5] Khun Farm Machinery, “Kuhn PZ Series,” [Online]. Available:

http://www.kuhn.co.uk/internet/prospectus.nsf/0/2465AB29471378D4C12576EE00
3555DB/$File/PZ_A05GB.pdf. [Accessed 13 November 2013].
[6] John Deere, “Operators Manual 131 Front Mower Conditioner,” Deere & Company,
2001.
[7] John Deere, “John Deere,” [Online]. Available:

http://www.deere.com/wps/dcom/en_INT/parts/attachment_system/attachment_syst
em.page?. [Accessed 3 November 2013].
[8] Claas, “Claas,” [Online]. Available:

http://www.claas.co.uk/blueprint/servlet/blob/98436/ae68cc5287084a4971c5790a2e
626018/168942-dataRaw.pdf. [Accessed 23 November 2013].
[9] John Deere, “John Deere,” [Online]. Available:

http://www.deere.com/en_INT/docs/product/equipment/mower_conditioner/
brochure/mower_conditioner.html. [Accessed 17 November 2013].
[10] Pottinger, “Pottinger,” [Online]. Available:

http://www.poettinger.co.uk/landtechnik/download/012.02.0813_Novacat_Novadisc
131
_en.pdf. [Accessed 21 November 2013].
[11] Krone, “Krone UK,” [Online]. Available:

http://www.krone-uk.com/english/products/disc-mowers/front-mounted-easycut/.
[Accessed 22 November 2013].
[12] Kverneland Group, “Kverneland,” [Online]. Available:

http://dc.kvernelandgroup.com/welcome?brand=&country[]=All
%20countries&country[]=global. [Accessed 21 Novemeber 2013].
[13] K. T. S. Eppinger, Product Design and Development, Mc Graw-Hill, 2012.
[14] Royal Academy of engineering, “Design Principles The engineers contribution to

soceity,” The Royal Academy of Engineeering, 2014.
[15] T. Buzan, Modern Mind Mapping for Smarter Thinking, Cardiff: Proactive Press,
2013.
[16] A. Darbyshire, Mechanical Engineering 2nd edition, Oxford: Newnes, 2008.
[17] M. Tooley and L. Dingle, BTEC National Engineering, Oxford: Newnes, 2002.
[18] Health and Safety Authority (2014) Leglisation. Dublin: Health and Safety
Authority.Available from http://www.hsa.ie/eng/Legislation/[Accessed 1 May 2014].
132
Appendices
To ensure the pressure was applied in the right area the reaction solutions was calculated
below.
Static Loading on 40mm pin
P=F/A
2697.75
P=
( 17.32 x 212)
P=0.73471 MPa
Reaction solutions
NODE FX FY FZ
TOTAL VALUES
VALUE -1557.6 2697.8 -0.36990E-06
FX= 0.73471 x (17.32 x 212) = 2697.73N

FY= 0.73471 x (10 x 212) = 1557.59N
Impact loading on 40mm pin
P=F/A
2697.5 x 5.76
P=
(17.32 x 212)
P=4.2315
Reaction solutions
TOTAL VALUES
NODE FX FY FZ
VALUE -8970.8 15538. -0.21304E-05
FX= 4.2315 x (10 x 212)=8970.78N

FY=4.231 x (17.32 x 212) = 15537.3N
133
Static loading on 36mm pin
P=F/A
2697.5 N
P=
( 15.59mm x 212mm)
P=0.8161 MPa
TOTAL VALUES
VALUE -1557.1 2697.0 0.23921E-09
0.8161 x ( 9 x 212 ) = 1557.11N
0.8161 x ( 15.59 x 212 )=2697N
Impact loading on 36 mm pin
P=F/A
2697.5 N x 5.76
P=
( 15.59mm x 212mm)
P=4.701 MPa
TOTAL VALUES
VALUE -8969.5 15536. 0.13375E-08
4.701 x (9 x212) = 8696.50N
4.701 x (15.59 x212) = 15536.18N
134
Static loading on pivot point
P=F/A
F
P=
A
Weight of mower body= 550kg
Force generated= 5395.5N
Because of symmetry the load was half
A= 17.32 x 70 = 1212.4mm2
5395.5 N
P=F/A 2
7343.68m m
P= 1.11256 Mpa
Verified from reaction solutions in ANSYS
NODE FX FY FZ
22422 -91.902
22424 -275.49
22505 -112.57
22582 -40.383
22603 -84.848
22625 -35.213
TOTAL VALUES
VALUE 778.79 0.65468E-07 -1348.9
FX=1.11256x700 = 778.79N
FZ=1.11256 x 1212.43 = 1348.90N
Impact loading on pivot point
P=F/A
( 2697.75/2) x 5.76
P=
1212.4
5395.5 N
P= 6.4083Mpa to be applied
7343.68m m2
2.22513 x700 = 1557.6N
135
2.22513 x 1212.43 = 2697.8N
Verified from reaction solutions in ANSYS

NODE FX FY FZ
22422 -529.35
22424 -1586.8
22505 -648.39
22582 -232.60
22603 -488.72
22625 -202.83
TOTAL VALUES
VALUE 4485.8 0.37947E-06 -7769.7
FX= 6.408 x700 = 4485.8N
FZ=6.408 x 1212.43 = 7769.7N
136

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A THESIS SUBMITTED FOR THE DEGREE OF BACHELOR OF ENGINEERING

(HONOURS) IN MECHANICAL ENGINEERING

Development of a front mounted mower for Malone Farm Machinery

DEPARTMENT OF MECHANICAL & INDUSTRIAL ENGINEERING

GALWAY-MAYO INSTITUTE OF TECHNOLOGY

DEPARTMENT OF MECHANICAL & INDUSTRIAL ENGINEERING..........................1

CAD: Computer Aided Draughting /Computer Aided Design............................................28

Figure 1.2 Feraboli front mower mounting.........................................................................30

Feraboli Agricultural Technologies.................................................................................33

Figure 1.4 Feraboli Agricultural Technologies...................................................................33

Patent license agreement...................................................................................................34

1.5 Agricultural machinery development in Mayo.....................................................34

1.6 Mowing conditioning process...............................................................................35

Figure 1.6 Front Mounted and Rear Mounted Mowers.......................................................36

Figure 1.7 Malone Pro Cut 960c..........................................................................................36

2.1 History of Mowers................................................................................................38

2.1.1 Introduction of drum and disc mowers..........................................................38

2.1.2 Evolution of modern mower/conditioner.......................................................40

2.2 Typical drive train.................................................................................................41

Figure 2.4 Typical front mower drive train arrangement....................................................41

2.3 Attachment Methods.............................................................................................42

2.4 Conditioning systems............................................................................................43

2.5 John Deere 131 front Mounted Mower.................................................................44

2.6 Pottinger front mounted mower............................................................................45

Figure 2.12 Pottinger Front mounted mower.......................................................................45

Figure 2.13 Krone Easy Cut front Mower...........................................................................46

2.8 Kverneland Tarrup 3632 FT..................................................................................47

Figure 2.14 Kverneland Tarrup Front Mounted Mower......................................................47

2.9 Claas 3500 FC PROFIL........................................................................................48

Figure 2.15: Claas Front Mounted Mower..........................................................................48

2.10 Comparison of existing mowers........................................................................50

3 Materials and Method..................................................................................................52

3.1 Product design and development..........................................................................52

3.2 Product development process................................................................................54

Figure 3.1 Kressy’s product development plan...................................................................54

Figure 3.2 Eppingers product development plan.................................................................54

Figure 3.3 Product development plan for front mounted mower........................................55

3.3 Concept development............................................................................................57

3.3.1 Mind mapping................................................................................................57

Figure 3.4 Mind map...........................................................................................................57

3.3.2 Design idea 1.................................................................................................58

Figure 3.5 Idea 1 Piston Damper Mechanism......................................................................58

3.3.3 Design idea 2.................................................................................................59

Figure 3.6 Idea 2 Scissors lift..............................................................................................59

3.3.4 Design idea 3.................................................................................................60

4 Materials and method...................................................................................................61

4.1 Design development..............................................................................................61

4.1.1 Use of 2D CAD in the design process...........................................................61

CAD benefits include:.........................................................................................................61

4.2 Use of 3D CAD in the design process..................................................................64

4.2.1 Receipt of original CAD model.....................................................................65

Figure 4.2 Malone Pro Cut 960c..........................................................................................65

Figure 4.3 Side panels..........................................................................................................67

4.2.3 Main Assembly..............................................................................................68

4.2.4 Pivot point......................................................................................................69

Figure 4.5 Main structural support member........................................................................69

Figure 4.6 Mower bed and spinal box section.....................................................................69

Figure 4.7 assembly tabs and slots.......................................................................................71

Figure 4.8 Pivot point assembly box section at 8o...............................................................71

Figure 4.9 Pivot point assembly mated at box section at 0o................................................72

Figure 4.10 Pivot Point assembly mated to box section at 4o..............................................72

4.2.5 Drive mechanisms..........................................................................................73

Figure 4.12 Central gear box...............................................................................................73

Figure 4.13 2D views of central gear box mounting brackets.............................................74