CHAPTER 1

INTRODUCTION

1.1 General

Coconut milk is a traditional food ingredient used in Southeast Asia, Oceania, South Asia,
and East Africa. It is also used for cooking in the Caribbean, tropical Latin America, and
West Africa, where coconuts were introduced during the colonial era. Coconut milk can be
used in both sweet and savory dishes. It is a traditional ingredient in curries and other dishes,
including desserts. At our home it takes more time to shred , squeeze coconut and take milk
from it. It is very time consuming and lengthy process . First we have to shred the coconut
then squeeze it then milk is separated using a filter. Using our machine this process can be
done easily and quickly.

1.2 Objectives of work

To construct a machine which can shred and squeeze coconut in one step. To decrease

number of instruments like separate shredder and squeezer for the normal coconut milk

extraction process. To reduce the time required for extract milk from coconut. To avoid

separate shredding, squeezing and filtering process.

1.3 Motivation of this work

Motivation for this work is our mothers, at house the coconut milk extraction process will
consume a large time. So job relatively fast. This machine is helpful in small scale food
making Industries. when this process become easy and fast they can finish their
1.4 Methodologies adopted
1. Collection of details.
2. Select most suitable design for machine.
3. Designing of components.
4. Calculations.
5. Fabrication.
6. Painting.
7. Testing.
1.5 Outline of the report
This report contains Literature review, Methodology, Working, Components
specification, Sample sketch, Results and discussions.
 CHAPTER 2
LITERATURE REVIEW

2.1 Pedro M.T. Marques, Ramiro C. Martins, et al.(2016)

They discovered Power loss and load distribution models including frictional effects for
spur and helical gears .They find the Friction between meshing gear teeth are amongst
the most influential power loss sources in a gearbox near nominal operating conditions.
Speed, load and coefficient of friction are some of the most important factors regarding
frictional losses in gears. The aim of this work is to introduce gear load sharing models
for spur and helical gears taking into account elastic and frictional effects allowing to do
more refined estimations of gear friction losses.

2.2 Surapol Raadnui et al.(2019)

Conduct study on Spur gear wear analysis as applied for tribological based predictive
maintenance diagnostics. This paper describes an experimental investigation on a pair of
spur gears in which wear and pitting were intentionally allowed to occur, namely,
moisture corrosion pitting, acid-induced corrosion pitting, hard contaminant-related
pitting
and mechanical induced wear. A back to back spur gear test rig was used throughout
32 test series. The tests samples of wear debris were collected and assessed through the
utilization of an optical microscope in order to correlate and compare the debris
morphology to pitting and wear degradation of the worn gears. In addition, weight loss
from all test gear pairs were assessed with utilization of statistical design. It was
observed that there were significant distinctions between both weight losses, wear debris
morphology generated from each induced pitting conditions and worn surface
characteristics. Thus, it should be possible to detect and diagnose gear pitting and wear
utilization of worn
surfaces, generated wear debris and quantitative measurement such as weight loss.
 CHAPTER 3
COMPONENTS DESCRIPTION
3.1 Motor
The motor we used is DC worm gear motor. In a worm gear motor, a worm gear setup
is used inside the motor. A worm drive is a gear arrangement in which a worm meshes
with a worm gear. The terminology is often confused by imprecise use of the term worm
gear to refer to the worm, the worm gear, or the worm drive as a unit. Like other gear
arrangements, a worm drive can reduce rotational speed or transmit higher torque. One
of the major advantages of worm gear drive units are that they can transfer motion in 90
degree. One motor is to run shredder and other is to run squeezer. The motor is 12V ,
30W, 60 rpm. The size of motor is also small so the weight and size of machine can be
reduced.
3.2 Gear
he gear used in this machine is spur gear. Spur gears or straight-cut-gears are the simplest
type of gear. They consist of a cylinder or disc with teeth projecting radially. These
simple gears are cost effective, durable and reliable. They are used in equipment to
transfer mechanical motion as well as control speed, power and torque. Gears are used
to transfer motion and torque between machine components . in this machine we use 3
gears.
3.3 Frame
It is the skeleton of the machine on which other components are mounted on it. It is made
with mild steel. It is joined by welding.
3.4 Shredder
Shredder is used to scrap coconut. The shredder is welded on the shaft. The shredder is
made from stainless steel.
3.5 Squeezer
Squeezer is used to squeeze the shredded coconut. In this machine we used screw
squeezer. The squeezer has a taper for better squeezing.
3.6 Hopper
A hopper is a large, pyramidal shaped container used in industrial processes to hold
particulate matter and move it .This Hopper is generally made of steel sheets by the use
of welding and riveting operations.
3.7 Bearing
Bearings is use to support the shafts . It also allow the rotation of shaft. In this machine
we use 3 ball bearing . Two SKF 6202 of them for the shaft of shredder and one SKF
6204 for the shaft of squeezer .Ball bearing is a type of rolling element bearing that uses
balls to maintain the seperation between the bearing races. The purpose of ball bearing is
to reduce rotational friction and support radial and axial loads. It achieves this by using
atleast two races to contain the balls and transmit the loads through the balls.
3.8 Shaft
Two shafts is used in this machine. One 15 mm for holding shredder and another 20 mm
one for holding squeezer. The shafts are made with mild steel.
3.9 Power supply
Our machine works with electric power. It can be also operate using a12V battery. The
power supply used in this machine is an AC-DC converter. It is for the working of DC
motors. Here we use 12V power supply.
3.10 Switch
The switch we used in this machine is a Double Pole Double Through (DPDT) switch.
Using this switch we can start the shredder, start squeezer and switch off the machine
(three positions).
3.11 Barrel
It is a cylinder like structure cover the screw squeezer. It has holes to extract milk from
squeezed coconut.
 CHAPTER 4
DESIGN CALCULATION

4.1 Motor

From research we have found that minimum force required to scrap coconut is 1-3 kgf. so
take F = 2 kgf

F = 2*9.81 = 19.62 N

Speed of shredder is taken as (N1) = 300 rpm

Maximum radius of shredder(rs) = 2.5*102

Torque required (T1) = Force*Perpendicular distance = F ∗ rs

=19.62*2.5*10-2N-m

T1 = 0.4905 N-m

We use single gear train for transmission.

No of teeth on small gear t1=14

No of teeth on big gear t2=78

Torque on small gear T1=0.4905 N-m

Torque on big gear T2=?

Speed of small gear N1=300 rpm

Speed of big gear N2=?

We know that,

t2 N 1 T 2
Gear Ratio ¿ = =
t1 N 2 T 1

N 1∗t 1 300∗14
From that N 2= = =53.84
t2 78

T 1∗T 2 0.4905∗78
T 2= = =2.737857 Nm
t1 14
so power of the motor

2∗π∗N 2∗T 2 2∗π∗53.84∗2.737587

P= =
60 60

P = 15.407751 W

Also by considering losses that may occur and the availability we selected the power required
for motor as 30 W.

4.2 Calculation of speed ratio

Input Speed N1 = 60 rpm

D 1 N 2 t1
Speed Ratio ¿ = =
D 2 N 1 t2

t 1∗N 1 78∗60
N2 = = =334 .2857 rpm
t2 14

N 2 334.857
Speed ratio = = =5.5714
N1 60

4.3 Design of spur gear

LEWIS AND BUCKINGHAM METHOD

Power(P) = 30W

Diameter of pinion(d1) = 11 mm

Speed of pinion(N1) = 334 rpm

No. of teeth of pinion(Z1) = 14

Z 2 78
Gear ratio, I = = =5.57
Z 1 14

Here the material used for both pinion and gear are same (CI). So we consider pinion as

the weakest material .

Strength of pinion = 600 kgf/cm2 (from PSG DB p.g-8.5 for CI)

HP∗75
Tangential load Ft =
Vm
 π∗d 1∗N 1
Vm = =0.1727 m/ s
60∗1000

Dynamic load Fd = Ft*Cv

3+V ❑m
Cv=velocity factor = from DB p.g 8.51 for Vm less than 10m/s
3

Cv=1.0575

So, Fd=18.469kgf

Strength of gear teeth Fs = σ ❑b∗b∗y∗P c

(b=3,Pc=3πm)

Lewis form factor y = 0.154− ( 0.912

Z )=0.888

Fs =1577.557m2 kgf

For safe design, Fs ≥ Fd

1577.557m2=18.469

m=
√ 18.469
1577.557
=0.10 cm

So module m=1 mm

Face width b = 3πm=3*π1=9.42 mm

Strength of gear tooth

Fs= 1577.557*0.1 = 157.755 kgf

Buckingham’s Dynamic Load

0.164∗V ∗(cb + F )
m t
Fd = F ❑t + 0.164∗V + 1.485 cb + F
m √ t

Deformation factor c=8150e , error e= 0.025(carefully cut gears)(DB pg 8.53 for CI

20 deg full depth)

C =8150*0.025=203.75
Vm = 0.1727*60=10.36 m/min

0.164∗10.362∗( ( 203.75∗0.942 ) +17.464)

Fd=17.464+ =32.8 kgf
0.164∗10.362+1.485 √203.75∗0.942+17.464

For safe design Fs ≥ Fd

Here Fs = 157.755 kgf , Fs =32.8 kgf

So design is safe Wear load Fw= d1Qkb

2 i 2∗5.57
Q= = =1.695 ¿for external gear)
i+1 5.57+1

σ 2∗sinα 1 1
K= ∗( + )
1.4 E 1 E2

Pressure angle α=20°

σc = 7500 kgf/cm2 (DB pg 8.5 for CI)

young’s modulus E1 and E2=1.1*106 kgf/cm2

k=
75002∗sin 20
1.4
∗
( 1
+
1
1.1∗10 1.1∗106
6 )
=24.985 kgf/cm2

Fw = 1.1*1.695*24.9*0.942 = 43.88 kgf

Fw >Fd . So design is safe.

CHAPTER 5

DESIGN

Figure5.1:Drawing
 Figure 5.2: Isometric View

Figure 5.3: Drawing of Squeezer

 CHAPTER6

MANUFACTURING PROCEDURE

6.1 Introduction

Manufacturing involves turning raw material to finished products, to be used for various
purposes. There are a large number of processes available. These processes can be broadly
classified into four categories.

1. Casting processes

Casting is a manufacturing process in which a liquid material is usually poured into a mould,
which contains a hollow cavity of the desired shape, and then allowed to solidify. The
solidified part is also known as a casting, which is ejected or broken out of the mould to
complete the process.

2. Forming processes

Forming is the process of obtaining the required shape and size on the raw material by
subjecting the material to plastic deformation through the application of tensile force,
compressive force, bending or shear force or combinations of these forces.

3. Fabrication processes

Metal fabrication is the creation of metal structures by cutting, bending and assembling
processes. It is a value-added process involving the creation of machines, parts, and structures
from various raw materials.

4. Material removal processes

Material removal process is a type of manufacturing process in which the final product is
obtained by removing excess metal from the stock.
6.2 Manufacturing steps

6.2.1 Material collection

Material collection is a process of gathering all the basic materials or components for
the manufacturing process. We collected materials and components according to our
needs and availability.

6.2.2 Metal cutting

Metal cutting or machining is the process of by removing unwanted material from a

block of metal in the form of chips. Usually, the portion that is fractured away is in
small sized pieces, called chips. In this type of setup to switch from one setup to next
we must change fixture of machine, clamp part in new fixture, select coordinate of
machine tool with respect to new location etc. Therefore, setup changes are time-
consuming and expensive, and so we should try to do the entire cutting process in a
minimum number of setup.

1. Drilling

Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-
section in solid materials. The bit (rotary cutting tool) is pressed against the
workpiece and rotated at rates from hundreds to thousands of revolutions per
minute. Tool in this mechanism has curved cutting teeth along its cylindrical
surface. The grooves created by the helical teeth are called flutes, and are
useful in pushing the chips out from the hole as it is being machined. Drilling
is not useful for very small diameter holes, since the tool may break and get
stuck in the work piece. For tight dimension control on hole diameter, we first
drill a hole that is slightly smaller than required size, and then use a special
type of drill called a reamer. Reaming has very low material removal rate, low
depth of cut, but gives good dimension accuracy

2. Turning

Turning is a machining process in which a cutting tool, typically a non-rotary

tool bit, describes a helix toolpath by moving more or less linearly while the
workpiece rotates.
 • Straight or Plain Turning

Plain turning originated in the watch industry and is used to manufacture

long, slim parts from rod stock or wire. On the plain lathe the rod material

is clamped in a chuck and pushed through a guide sleeve. There are plain
lathes with rigid and those with follower guide sleeve.

• Taper Turning

When the diameter of a piece changes uniformly from one end to the other, the
piece is said to be tapered. Taper turning as a machining operation is the
gradual reduction in diameter from one part of a cylindrical workpiece to
another part. Tapers can be either external or internal.

6.2.3 Metal joining

The metal joining is a process of joining two or more metal parts. The common metal

joining processes are welding, riveting, bolting, etc.

1. Welding

Welding is a process for joining similar metals. Welding joins metals by melting and
fusing. Most welding involves ferrous-based metals such as steel and stainless steel.
Weld joints are usually stronger than or as strong as the base metals being joined. In
this process an electrical machine supplies current to an electrode holder which carries
an electrode which is normally coated with a mixture of chemicals or flux. The weld
is initiated by tapping the tip of the electrode against the work piece which initiates an
electric arc. This instantly produces a molten pool and the end of the electrode
continuously melts into this pool and forms the joint.

6.2.4 Surface finishing

Surface finish, also known as surface texture or surface topography, is the nature of a surface
as defined by the three characteristics of lay, surface roughness, and waviness. It comprises
the small, local deviations of a surface from the perfectly flat ideal (a true plane).
 1. Surface Grinding

Surface grinding is the most common of the grinding operations. It is a finishing

process that uses a rotating abrasive wheel to smooth the flat surface of metallic or
non-metallic materials to give them a more refined look by removing the oxide layer
and impurities on work piece surfaces. This will also attain a desired surface for a
functional purpose.

6.2.5 Assembly

An assembly line is a manufacturing process (often called a progressive assembly) in which

parts (usually interchangeable parts) are added as the semi-finished assembly moves from
workstation to workstation where the parts are added in sequence until the final assembly is
produced.

6.2.6 Painting

Painting is the practice of applying paint, pigment, color or other medium to a solid surface.
The medium is commonly applied to the base with a brush, but other implements, such as
knives, sponges, and airbrushes, can be used. In art, the term painting describes both the act
and the result of the action.
 CHAPTER 7

PARTS FABRICATION

Fabrication is started with arc welding of flanges together to make frame. Then the
components like shafts, gears, bearings, shredder, and motors are purchased and placed on
the frame by using welding process. Then we collected threaded squeezer as per the required
operation. Then some dimension changes are applied on the squeezer design by using lathe
operation as satisfying our requirements. Then we collected a cylindrical pipe having suitable
dimension for casing of screw thread. Some of the holes are provided on the squeezer casing
(barrel) by drilling operation. After made a hopper for collecting coconut residue by cutting
the sheet metal (1.5 mm thickness) and which is placed upon the squeezer casing. A DPDT
switch is provided on the machine by welding process.

7.1 Parts Fabricated

1. Hopper

• Material : Mild steel

• Size : 200*200 mm at the top, 90*40 mm at the bottom, 195 mm height

• Process : cutting and welding

2. Shredder Shaft

• Material : Mild steel

• Size : dia 15 mm

• Process : cutting

3. Squeezer shaft

• Material : Mild steel

• Size : dia 20 mm

• Process : cutting

4. Stand

• Material : Mild steel

 • Size : 610*305 mm , height :- 26 mm

• Process : cutting and Welding

5. Barrel

• Material : Mild steel

• Size : 50 mm outer diameter 46 mm inner diameter

• Process : Cutting and drilling

 CHAPTER 8

WORKING PRINCIPLE

The working procedure of this machine was starting by switching the machine on
using DPDT switch.

Then the shredder will start rotating , so we can shred the coconut.

Thus the shredded coconut will fall into the hopper.

This shredded coconut is moved to squeezer by a hopper.

Then the shredder is switched off and squeezer is switched on using the switch.

Then the shredded coconut is moved to the threads of squeezer and get squeezed.

Then the coconut milk will squeezed out and the residue is separately collected.

After the use machine is switched off.

 CHAPTER 9

ADVANTAGES & DISADVANTAGES

9.1 Advantages

• Easy and quick process.

• Coconut can be shredded and squeezed using the same machine.

• Time consumed is less.

• Less cost.

• Low sound.

• Can be used conveniently.

• Do not create any harmful to the environment.

9.2 Disadvantages

• Some amount of coconut shredded remains after squeezing it.

• The coconut should be hold in our hands during shredding.

 CHAPTER 10

LIST OF MATERIALS

SI.NO NAME OF COMPONENT QUANTITY MATERIAL

1 Power window motor 2 DC Motor
2 Ball bearing 3 C.I
3 Shaft 2 M.S.Solid
4 Hopper sheets 1 M.S
5 Spur gear 3 C.I
6 Squeezer casing 1 M.S
7 Shredder 1 C.I
8 Screw squeezer 1 Stainless Steel
9 Frame - Mild Steel
10 Switch 1 DPDT Switch
11 Adaptor 1 AC-DC Adaptor

Table 10.1 : List of Materials

 CHAPTER 11

COST ESTIMATION

Before going to cost estimation of the coconut shredder with squeezer apparatus ,a small
introduction of cost analysis is given. Cost of the various materials and the appropriate
allocation of expenditure to determine the cost of products or services and presentation of
suitably arranged data for purpose of control and guidelines of management uses are given.
The following uses are achieved by cost estimation:

1. To determine the cost of each article.

2. It helps in reducing the total cost of manufacturer.

3. It suggests changes in design, when the cost is high.

Total cost of the system = cost of purchased parts + overhead charges +other expense

SI.NO NAME OF COMPONENT QUANTITY Total Cost

1 Power window motor 2 3800
2 Ball bearing 3 500
3 Shaft 2 1000
4 Hopper sheets 1 950
5 Spur gear 3 800
6 Squeezer casing 1 300
7 Shredder 1 200
8 Screw squeezer 1 400
9 Frame - 300
10 Switch 1 60
11 Adaptor 1 440
 CHAPTER12

CONCLUSION

An ideal device for extract milk from coconut easily and quickly are designed. The coconut is
shredded and squeezed within a single machine . The squeezed milk is separated using a
filter. The time consumed for this process is less. The requirement of other machines is not
necessary for our project .The design analysis and fabrication of this project have done with
utmost care. The cost estimation has also done.
 CHAPTER 13

FUTURE SCOPE

• The shredding of coconut can be done automatically without holding it with hand.

• The machine can be made in to big size and can use for more input and more

output.
 REFERENCES

1. Marques, Pedro MT, Ramiro C. Martins, and Jorge HO Seabra. ”Power loss and load
distribution models including frictional effects for spur and helical gears.” Mechanism and
Machine Theory 96 (2016): 1-25.

2. Raadnui, Surapol. ”Spur gear wear analysis as applied for tribological based predictive
maintenance diagnostics.” Wear 426 (2019): 1748-1760.

3. Yoon, K. Y., and Singiresu S. Rao. ”Dynamic load analysis of spur gears using a new
tooth profile.” (1996): 1-6.