Introduction

There are many electrically operated power bud cutting machine of different
configuration and different manufactures are available for the use in machine shop. These
machines can cut rods of different material precisely at very fast rate but they can cut rods of
one material at a time which means they can’t able to cut dissimilar material at a same time.
Now in industry, it is necessary to cut sugarcane buds with very high rate to achieve mass
production requirement. So there is need to move for a new technology which gives us a
mass production with less time and less energy input. It is impossible to depend upon
conventional bud cutting machine. By using this two way bud cutting machine the two buds,
can be cut the simultaneously to achieve high speed cutting rate and mass production for
maximum benefits in manufacturing industries. This machine overcomes the drawbacks and
limitation of single frame bud cutting machine. It can be used in a small workshops and
industries as it is available in very low price and its smaller size and high efficiency. This
paper focous on presents the manufacture and idea of two way bud cutting removing machine
predominantly conveyed for creation based ventures. Businesses are fundamentally implied
for creation of valuable merchandise and ventures at low generation cost, Machinery cost and
low stock cost. Today in this world each errand have been made snappier and quick because
of innovation progression yet this headway likewise requests colossal speculation and
consumption, each industry wants to make high efficiency rate keeping up the quality and
standard of the item at low normal cost. We have developed a prototype model, which is
efficient and do multiple cutting operations. These machines can be utilized as a part of
remote spots where power is customary. It is composed as a convenient one which can be
utilized for cutting in different spots

Justification

In manual harvesting to cut one acre of sugarcane 15-16 labors are required they take
3 days to cut one acre. By using this machine problem of the labor crises can be reduced.
Comparing with manual harvesting only 18% of labors are required, it makes the process
faster hence reduces most of the harvesting time and labor required to operate the machine is
also less. This machine is helpful for both small and big farmers. (Ratod et al. 2013) To
overcome these problems this project work aims to develop low cost sugarcane harvesting
machine which is more efficient and having simple mechanism for cutting the sugarcane at a
faster rate. (Siddaling and Ravaikiran 2015) The purpose of developing this machine is to
reduce cost and time required for sugarcane harvesting. Sugarcane harvesting machine which
is economical, more efficient and cuts the sugarcane at faster rate and it will be helpful for
small scale farmers, unskilled labors can also operate without difficulty. By using this
harvesting machine, we can also solve the problem of labor shortage.

Physical Properties of Sugarcane Crops

Blackburn described the sugarcane as a tall tropical grass with a single un-branched
stem of average height in the range of 3 to 4m with a stem diameter ranges from 3 to 5cm
depending on the species. Moore and Misstated that the sugarcane is a large tropical grass
that produces multiple stems or culms each of which consist of a series of nodes separated by
internodes. After germination, the terminal vegetative bud of each shoot lays down a series of
nodes, each with a dormant bud and one or more rows of root primordial and a growth ring.
The internodes consist of sucrose storing parenchyma cells and vascular tissue. The stalk of
sugarcane is the major storage area for photosynthate (sucrose) within the sugarcane plant,
rather than fruit or seed structures. Stalk is also known as "millable cane". The top of the
stalk is relatively low in sucrose and therefore is of little value to the mill. The stalk consists
of segments called joints. Each joint is made up of a node and an inter node. The node is the
place where the leaf attaches to the stalk.
 Literature view
Kiatiwait et al. (1992) developed a selph-propelled walking type sugarcane harvester-
windrower in Thailand. The machine is a one row single-axle walking-behind-type. It works
on the principle of impact cutting by knife blades. As the machine moves forward along the
row, the cluster of cane stalks is guided from the divider by a two sets of lugged chains and a
spring loaded guide frame. At the narrowest point of guided path, the canes are cut by blades
of the base cutter, revolving at peripheral speed approximately 42 m/s. A pair of solid rubber-
gage tractor wheels mounted in the front part of the machine prevents the base cutter blade
from striking the ground and control the height of cut. The machine type is4GZ-9 whole stalk
harvester, mounted on 11-14.7 kW hand tractor. Its productivity is 0.1-0.15 ha/h, and it is
adapted to row spacing ≥1.0 m. shifting a lock-pin along the shaft to make adjustment for
various spacing along the adjacent rows. Viator and Wang (2321-3051) studies that the green
harvesting method can also have negative effects on cane yield in certain environments
because the trash layer can lower the soil temperature, which can slow down early plant
growth and increase the risk of frost damage in young plants during freeze or near- freeze
events summarizes the weaknesses of green cane harvesting practices. Sandhu et al. (4337-
4343) showed that green cane harvesting method could reduce Lesser Cornstalk Borer
damage to sugarcane because the trash blanket can inhibit the egg deposition and increase the
larval mortality.

In sugarcane bud chipping operation what is the advantage and limitation in existing
machine. An exhaustive literature review has been done to consume basic idea about what
actually done. According to Ningappa H. Kuri[1], in existing machine people uses traditional
process in which hand operated leaver is installed to cut the bud from sugarcane and there is
setting arrangement there is chance of occurring the muscle pain ,cramps etc. the injuries
while operation performed is also occurs. So to overcome these problems, we proposed the
peddle operated machine which deals to reduced manual effort require is less and no muscle
pain and cramps is occurred during operation and it can be prevent from the injuries while
performing operation. As we install pedal instead of hand lever, according to ergonomics
aspects the effort gets reduced. As the hand take much more effort compared with the foot.
By using two side cutting tool, two buds cut at same time. The effort requires for cutting
operation is reduced. So the time consuming related to cutting operation is also reduced. The
machine made by suraj s. magdum [2]there is one disadvantage, we found that tool gets blunt
after taking continuous cutting operation. So to overcome this problem we used three
alternative tool as per the various size of sugarcane. As alternative tool is used the production
may not hamper. According to Sanjay Patil [3],In another traditional machine there is only
single cutting tool is used known as “scooping tool”. Though the single scooping tool is used
in existing machine slippage occurs and due to that there is possibility to damage and wastage
of sugarcane while cutting. To avoid this, we implement clamping device while cutting
sugarcane to hold properly. Because of proper holding, the bud is cut in proper shape and size
and reduce the wastage of sugarcane. As implementation of holding device leads to reduced
injuries. Also we proposed the length of the table. We increase the length of table that support
the sugarcane from bending and avoid slippage. Because of this proper shape and size of bud
can be cutted from the sugarcane. In another research paper we found that the traditional
machine made by the Roshanlal Vishvakarma[4] a former of small village in Madhya
Pradesh. in which he used single cutting tool. as the single cutting tool is used productivity of
cutting bud of the machine is reduced .in our proposed machine we installed two side chipper
tool which is able to cut two bud pieces at a same time from sugarcane at a single notch,
that’s why the productivity increases by cutting two buds at same time.

1. Godfrey P. Caldwell and Nigel W. Meek- The present invention relates to “crop cutting
apparatus” and is concerned in particular, but not exclusively, with mowing apparatus
suitable for cutting grass and other fodder crops.

2. Ingo Boeing and Andreas Haffert- The present invention relates to an “agricultural
harvesting machine”. For the operator of a harvesting machine, it is imperative that the
parameters of the machine components be set correctly in order to ensure that a harvesting
process is attained that reaches a desired harvesting goal to be attained at the end of the
harvesting process chain.
OBJECTIVES

 To reduce the man power.

 To maintain the accuracy in pipe cutting process.

 To perform the most rigid operation with high speed cutting.

 To develop automation unit for the drill so that m/c can easily be adopted in today‟s
automated plants.

 To fulfill need of mass production in shortest possible time.

NEED FOR BUD CUTTER

The need for sugar cane bud chipper is only for the farmers, where they are using an
full size of sugarcanes in the field for the plantation purpose, while using this sugar cane bud
chipper we can cut it down in to small pieces, compact in size it can also use for plantation
from this we save the wastage of remaining portion of the sugar cane.

Fig. : Traditional Method

Fig. : Bud Chipping Method Sugarcane

 RESEARCH METHODOLOGY

Design

Define Specifications
Of Product

Study alternative
Mechanism For
product and Selecting

Prepare General Layout

configuration

Prepare Assembly And

Detailed Drawings

Fabrication

Working principle
Here our project based on Dc power which is extracted from 12volt dc battery. Which drives
12volt dc wiper motor having rated torque 20kgcm. When motor starts rotating cam get
rotated and links attached to it too.

As the link get motion from circulating cam pushing rods get in motion. Links convert
rotory motion of cam into reciprocation motion of pushing rod. As cutter weld to pushing
rods gets in action .And if we put sugarcane in line if action of cutter it get cut.

Design
 Components to be used

1. Wiper Motor

An induction motor or asynchronous motor is an AC electric motor in which

the electric current in the rotor needed to produce torque is obtained
by electromagnetic induction from the magnetic field of the stator winding.[1] An
induction motor can therefore be made without electrical connections to the rotor.
 An induction motor's rotor can be either wound type or squirrel-cage type.
[a]

Three-phase squirrel-cage induction motors are widely used as industrial

drives because they are self-starting, reliable and economical. Single-phase induction
motors are used extensively for smaller loads, such as household appliances like fans.
Although traditionally used in fixed-speed service, induction motors are increasingly
being used with variable-frequency drives (VFD) in variable-speed service. VFDs
offer especially important energy savings opportunities for existing and prospective
induction motors in variable-torque centrifugal fan, pump and compressor load
applications. Squirrel cage induction motors are very widely used in both fixed-speed
and variable-frequency drive applications.
Principle operation

In both induction and synchronous motors, the AC power supplied to the

motor's stator creates a magnetic field that rotates in synchronism with the AC
oscillations. Whereas a synchronous motor's rotor turns at the same rate as the stator
field, an induction motor's rotor rotates at a somewhat slower speed than the stator
field. The induction motor stator's magnetic field is therefore changing or rotating
relative to the rotor. This induces an opposing current in the induction motor's rotor,
in effect the motor's secondary winding, when the latter is short-circuited or closed
through an external impedance.[28] The rotating magnetic flux induces currents in the
windings of the rotor,[29] in a manner similar to currents induced in a transformer's
secondary winding(s).

The induced currents in the rotor windings in turn create magnetic fields in the rotor
that react against the stator field. Due to Lenz's Law, the direction of the magnetic
field created will be such as to oppose the change in current through the rotor
windings. The cause of induced current in the rotor windings is the rotating stator
magnetic field, so to oppose the change in rotor-winding currents the rotor will start to
rotate in the direction of the rotating stator magnetic field. The rotor accelerates until
the magnitude of induced rotor current and torque balances the applied mechanical
load on the rotation of the rotor. Since rotation at synchronous speed would result in
no induced rotor current, an induction motor always operates slightly slower than
synchronous speed. The difference, or "slip," between actual and synchronous speed
varies from about 0.5% to 5.0% for standard Design B torque curve induction motors.
 The induction motor's essential character is that it is created solely by induction
[30]

instead of being separately excited as in synchronous or DC machines or being self-

magnetized as in permanent magnet motors.[28]

For rotor currents to be induced, the speed of the physical rotor must be lower than
that of the stator's rotating magnetic field (); otherwise the magnetic field would not
be moving relative to the rotor conductors and no currents would be induced. As the
speed of the rotor drops below synchronous speed, the rotation rate of the magnetic
field in the rotor increases, inducing more current in the windings and creating more
torque. The ratio between the rotation rate of the magnetic field induced in the rotor
and the rotation rate of the stator's rotating field is called "slip". Under load, the speed
 drops and the slip increases enough to create sufficient torque to turn the load. For this
reason, induction motors are sometimes referred to as "asynchronous motors".[31]

An induction motor can be used as an induction generator, or it can be unrolled to

form a linear induction motor which can directly generate linear motion. The
generating mode for induction motors is complicated by the need to excite the rotor,
which begins with only residual magnetization. In some cases, that residual
magnetization is enough to self-excite the motor under load. Therefore, it is necessary
to either snap the motor and connect it momentarily to a live grid or to add capacitors
charged initially by residual magnetism and providing the required reactive power
during operation. Similar is the operation of the induction motor in parallel with a
synchronous motor serving as a power factor compensator. A feature in the generator
mode in parallel to the grid is that the rotor speed is higher than in the driving mode.
Then active energy is being given to the grid.[2] Another disadvantage of induction
motor generator is that it consumes a significant magnetizing current I0 = (20-35)%.

2. DC battery
 A battery is a device consisting of one or more electrochemical cells with external
connections[1] for powering electrical devices such as flashlights, mobile phones, and electric
cars. When a battery is supplying electric power, its positive terminal is the cathode and its
negative terminal is the anode.[2] The terminal marked negative is the source of electrons that
will flow through an external electric circuit to the positive terminal. When a battery is
connected to an external electric load, a redox reaction converts high-energy reactants to
lower-energy products, and the free-energy difference is delivered to the external circuit as
electrical energy.[3] Historically the term "battery" specifically referred to a device composed
of multiple cells, however the usage has evolved to include devices composed of a single cell.
[4]

Primary (single-use or "disposable") batteries are used once and discarded, as

the electrode materials are irreversibly changed during discharge; a common example is
the alkaline battery used for flashlights and a multitude of portable electronic
devices. Secondary (rechargeable) batteries can be discharged and recharged multiple times
using an applied electric current; the original composition of the electrodes can be restored by
reverse current. Examples include the lead-acid batteries used in vehicles and lithium-
ion batteries used for portable electronics such as laptops and mobile phones.

Batteries come in many shapes and sizes, from miniature cells used to power hearing aids and
wristwatches to small, thin cells used in smartphones, to large lead acid batteries or lithium-
ion batteries in vehicles, and at the largest extreme, huge battery banks the size of rooms that
provide standby or emergency power for telephone exchanges and computer data centers.

Batteries have much lower specific energy (energy per unit mass) than common fuels such as
gasoline. In automobiles, this is somewhat offset by the higher efficiency of electric motors in
converting chemical energy to mechanical work, compared to combustion engines.

Batteries convert chemical energy directly to electrical energy. In many cases, the electrical

energy released is the difference in the cohesive or bond energies of the metals, oxides, or
molecules undergoing the electrochemical reaction. For instance, energy can be stored in Zn
or Li, which are high-energy metals because they are not stabilized by d-electron bonding,
unlike transition metals. Batteries are designed such that the energetically
favorable redox reaction can occur only if electrons move through the external part of the
circuit.
A battery consists of some number of voltaic cells. Each cell consists of two half-
cells connected in series by a conductive electrolyte containing metal cations. One half-cell
includes electrolyte and the negative electrode, the electrode to which anions (negatively
charged ions) migrate; the other half-cell includes electrolyte and the positive electrode, to
which cations (positively charged ions) migrate. Cations are reduced (electrons are added) at
the cathode, while metal atoms are oxidized (electrons are removed) at the anode. [14] Some
cells use different electrolytes for each half-cell; then a separator is used to prevent mixing of
the electrolytes while allowing ions to flow between half-cells to complete the electrical
circuit.

The electrical driving force or  across the terminals of a cell is known as the terminal voltage
(difference) and is measured in volts.[17] The terminal voltage of a cell that is neither charging
nor discharging is called the open-circuit voltage and equals the emf of the cell. Because of
internal resistance,[18] the terminal voltage of a cell that is discharging is smaller in magnitude
than the open-circuit voltage and the terminal voltage of a cell that is charging exceeds the
open-circuit voltage.[19] An ideal cell has negligible internal resistance, so it would maintain a
constant terminal voltage of  until exhausted, then dropping to zero. If such a cell maintained
1.5 volts and produce a charge of one coulomb then on complete discharge it would have
performed 1.5 joules of work.[17] In actual cells, the internal resistance increases under
discharge[18] and the open-circuit voltage also decreases under discharge. If the voltage and
resistance are plotted against time, the resulting graphs typically are a curve; the shape of the
curve varies according to the chemistry and internal arrangement employed.

The voltage developed across a cell's terminals depends on the energy release of the chemical
reactions of its electrodes and electrolyte. Alkaline and zinc–carbon cells have different
chemistries, but approximately the same emf of 1.5 volts; likewise NiCd and NiMH cells
have different chemistries, but approximately the same emf of 1.2 volts. [20] The high
electrochemical potential changes in the reactions of lithium compounds give lithium cells
emfs of 3 volts or more.

3. Ms square pipe
 Square hollow sections or square tubes are cold formed and welded from either hot rolled,
cold rolled, pre-galvanized or stainless steel.

In order to form the square steel section the appropriate mother tube, a round steel tube, has
to be formed first. From a round tube rolls are used that progressively press the round tube
into a square hollow section. This is all done inline. For example: A round tube with an
outside diameter of 50.8 is pressed into a 40x40 square tube.

Square and rectangular steel tubes have the advantage of being stronger in bending while a
round hollow sections has more stiffness in twisting.

EN Specifications:

 EN 10305-2 on welded cold drawn precision steel hollow sections

 EN 10305-3 on welded and rolled to size precision steel hollow tube, direct of mill.
 EN 10305-5 on welded and rolled to size square and rectangular precision steel tubes.
 The EN specifications stated above replaced the following DIN (German institute for
standardisation) specifications:

 DIN 2393 on welded cold drawn precision steel hollow sections was replaced by EN 10305-2
 DIN 2394 on welded and rolled to size precision steel hollow tube was replaced by EN
10305-3
 DIN 2395 on welded and rolled to size square and rectangular precision steel tubes was
replaced by EN 10305-4
For all structural tubing Tubecon can manufactured according to the following specifications:

 EN 10219 on cold formed welded structured hollow sections of non-alloy and fine grain
steels
 EN 10219-1 covers all the technical delivery conditions
 EN 10219-2 contains all information required regarding tolerances, dimensions and sectional
properties.

4. Ms Round bars

Steel is an alloy of iron and carbon, and sometimes other elements

like chromium. Because of its high tensile strength and low cost, it is a major
component used
in buildings, infrastructure, tools, ships, trains, automobiles, machines, appliances,
and weapons.

Iron is the base metal of steel. Iron is able to take on two crystalline forms
(allotropic forms), body centered cubic and face-centered cubic, depending on its
temperature. In the body-centered cubic arrangement, there is an iron atom in the
center and eight atoms at the vertices of each cubic unit cell; in the face-centered
cubic, there is one atom at the center of each of the six faces of the cubic unit cell and
eight atoms at its vertices. It is the interaction of the allotropes of iron with the
alloying elements, primarily carbon, thatgives steel and cast iron their range of unique
properties.

In pure iron, the crystal structure has relatively little resistance to the iron

atoms slipping past one another, and so pure iron is quite ductile, or soft and easily
formed. In steel, small amounts of carbon, other elements, and inclusions within the
iron act as hardening agents that prevent the movement of dislocations.

The carbon in typical steel alloys may contribute up to 2.14% of its weight.
Varying the amount of carbon and many other alloying elements, as well as
controlling their chemical and physical makeup in the final steel (either as solute
elements, or as precipitated phases), slows the movement of those dislocations that
make pure iron ductile, and thus controls and enhances its qualities. These qualities
include the hardness, quenching behavior, need for annealing, tempering
behavior, yield strength, and tensile strength of the resulting steel. The increase in
steel's strength compared to pure iron is possible only by reducing iron's ductility.

Steel was produced in bloomery furnaces for thousands of years, but its large-
scale, industrial use began only after more efficient production methods were devised
in the 17th century, with the introduction of the blast furnace and production
of crucible steel. This was followed by the open-hearth furnace and then the Bessemer
process in England in the mid-19th century. With the invention of the Bessemer
process, a new era of mass-produced steel began. Mild steel replaced wrought iron.

Further refinements in the process, such as basic oxygen steelmaking (BOS),

largely replaced earlier methods by further lowering the cost of production and
increasing the quality of the final product. Today, steel is one of the most common
manmade materials in the world, with more than 1.6 billion tons produced annually.
Modern steel is generally identified by various grades defined by assorted standards
organizations.
 5. 6204 ball bearing

A bearing is a machine element that constrains relative motion to only the desired motion,
and reduces friction between moving parts. The design of the bearing may, for example,
provide for free linear movement of the moving part or for free rotation around a fixed axis;
or, it may prevent a motion by controlling the vectors of normal forces that bear on the
moving parts. Most bearings facilitate the desired motion by minimizing friction. Bearings
are classified broadly according to the type of operation, the motions allowed, or to the
directions of the loads (forces) applied to the parts.

Rotary bearings hold rotating components such as shafts or axles within mechanical systems,

and transfer axial and radial loads from the source of the load to the structure supporting it.
The simplest form of bearing, the plain bearing, consists of a shaft rotating in a
hole. Lubrication is used to reduce friction. In the ball bearing and roller bearing, to reduce
sliding friction, rolling elements such as rollers or balls with a circular cross-section are
located between the races or journals of the bearing assembly. A wide variety of bearing
designs exists to allow the demands of the application to be correctly met for maximum
efficiency, reliability, durability and performance.

The term "bearing" is derived from the verb "to bear";[1] a bearing being a machine element
that allows one part to bear (i.e., to support) another. The simplest bearings are bearing
surfaces, cut or formed into a part, with varying degrees of control over the form,
size, roughness and location of the surface. Other bearings are separate devices installed into
a machine or machine part. The most sophisticated bearings for the most demanding
applications are very precise devices; their manufacture requires some of the highest
standards of current technology.

A ball bearing is a type of rolling-element bearing that uses balls to maintain the separation

between the bearing races.

The purpose of a ball bearing is to reduce rotational friction and

support radial and axial loads. It achieves this by using at least two races to contain the balls
and transmit the loads through the balls. In most applications, one race is stationary and the
other is attached to the rotating assembly (e.g., a hub or shaft). As one of the bearing races
rotates it causes the balls to rotate as well. Because the balls are rolling they have a much
lower coefficient of friction than if two flat surfaces were sliding against each other.

Ball bearings tend to have lower load capacity for their size than other kinds of rolling-
element bearings due to the smaller contact area between the balls and races. However, they
can tolerate some misalignment of the inner and outer races.

6. 6204 UCF bearing

. Item: UCF-212 Bearing

. Type: Four bolt Flanged Bearing
. Bolt Size: M20
. Basic Load Dynamic (Cr): 52,400 N
. Basic Load Static (Cor): 36,200 N

ISUTAMI UCFC flange cartridge mounted bearing unit, also known as UCFC 4-bolt round
flanged housing with bearing, consists of a circular flanged housing and an outer spherical
ball bearing, it is usually used when the bearing mounting surface is perpendicular to the
shaft. Like 4-bolt square flange mounted bearing unit, the center of the flanged housing is a
spherical inner ring for mounting spherical bearings of an appropriate size. It is usually made
of cast iron and will be painted or galvanized according to customer's specific requirements.
The housing has a built-in grease nipple to help with bearing lubrication and also to prevent
some problems such as internal wear of the bearing. The built-in spherical bearing is a ball
bearing with a dust-proof rubber seal on both sides of it. The circular inner ring of the bearing
as well as the four evenly distributed bolt holes on the flange are machined for high precision.

The diameter of the inner bore and the bearing housing bolts of the bearing unit is shown in
inch or metric unit. The round flange housing of the UCFC flange cartridge mounted bearing
unit provided by ISUTAMI is a one-piece. The series is with normal duty, and it has a wide
inner ring, the extension of the inner ring for fixing the shaft is a set screw locking type. The
bore diameter ranges from 1/2 inch up to 2-7/16 inches. The inserted bearings in ISUTAMI
cast iron mounted bearing unit are fitted with sufficient advanced grease after assembly.
There is no need for replenishment during initial operation in new installations. The normal
grease content of the bearing unit is approximately one-third to one-half of the internal space
inside the bearing.

Manufacturing processes

Welding process

Arc welding

Arc welding is a type of welding that uses a welding power supply to create an electric arc
between an electrode and the base material to melt the metals at the welding point. They can
use either direct (DC) or alternating (AC) current, and consumable or non-consumable
electrodes. The welding region is usually protected by some type of shielding gas, vapor, or
slag. Arc welding processes may be manual, semi-automatic, or fully automated. First
developed in the late part of the 19th century, arc welding became commercially important in
shipbuilding during the Second World War. Today it remains an important process for the
fabrication of steel structures and vehicles.

Power supplies

Engine driven welder capable of AC/DC welding.

A diesel powered welding generator (the electric generator is on the left) as used in
Indonesia.

To supply the electrical energy necessary for arc welding processes, a number of different
power supplies can be used. The most common classification is constant current power
supplies and constant voltage power supplies. In arc welding, the voltage is directly related to
the length of the arc, and the current is related to the amount of heat input. Constant current
power supplies are most often used for manual welding processes such as gas tungsten arc
welding and shielded metal arc welding, because they maintain a relatively constant current
even as the voltage varies. This is important because in manual welding, it can be difficult to
hold the electrode perfectly steady, and as a result, the arc length and thus voltage tend to
fluctuate. Constant voltage power supplies hold the voltage constant and vary the current, and
as a result, are most often used for automated welding processes such as gas metal arc
welding, flux cored arc welding, and submerged arc welding. In these processes, arc length is
kept constant, since any fluctuation in the distance between the wire and the base material is
quickly rectified by a large change in current. For example, if the wire and the base material
get too close, the current will rapidly increase, which in turn causes the heat to increase and
the tip of the wire to melt, returning it to its original separation distance.[1]

The direction of current used in arc welding also plays an important role in welding.
Consumable electrode processes such as shielded metal arc welding and gas metal arc
welding generally use direct current, but the electrode can be charged either positively or
negatively. In welding, the positively charged anode will have a greater heat concentration
(around 60%)[2] and, as a result, changing the polarity of the electrode has an impact on weld
properties. If the electrode is positively charged, it will melt more quickly, increasing weld
penetration and welding speed. Alternatively, a negatively charged electrode results in more
shallow welds.[3] Non-consumable electrode processes, such as gas tungsten arc welding, can
use either type of direct current (DC), as well as alternating current (AC). With direct current
however, because the electrode only creates the arc and does not provide filler material, a
positively charged electrode causes shallow welds, while a negatively charged electrode
makes deeper welds.[4] Alternating current rapidly moves between these two, resulting in
medium-penetration welds. One disadvantage of AC, the fact that the arc must be re-ignited
after every zero crossing, has been addressed with the invention of special power units that
produce a square wave pattern instead of the normal sine wave, eliminating low-voltage time
after the zero crossings and minimizing the effects of the problem.[5]

Duty cycle is a welding equipment specification which defines the number of minutes, within
a 10-minute period, during which a given arc welder can safely be used. For example, an
80 A welder with a 60% duty cycle must be "rested" for at least 4 minutes after 6 minutes of
continuous welding.[6] Failure to observe duty cycle limitations could damage the welder.
Commercial- or professional-grade welders typically have a 100% duty cycle.
Consumable electrode methods
Main articles: Shielded metal arc welding, Gas metal arc welding, Flux-cored arc welding
and Submerged arc welding

Shielded metal arc welding

One of the most common types of arc welding is shielded metal arc welding (SMAW), which
is also known as manual metal arc welding (MMAW) or stick welding. An electric current is
used to strike an arc between the base material and a consumable electrode rod or stick. The
electrode rod is made of a material that is compatible with the base material being welded and
is covered with a flux that gives off vapors that serve as a shielding gas and provide a layer of
slag, both of which protect the weld area from atmospheric contamination. The electrode core
itself acts as filler material, making a separate filler unnecessary. The process is very
versatile, requiring little operator training and inexpensive equipment. However, weld times
are rather slow, since the consumable electrodes must be frequently replaced and because
slag, the residue from the flux, must be chipped away after welding. [7] Furthermore, the
process is generally limited to welding ferrous materials, though specialty electrodes have
made possible the welding of cast iron, nickel, aluminium, copper and other metals. The
versatility of the method makes it popular in a number of applications including repair work
and construction.[8]

Gas metal arc welding (GMAW), commonly called MIG (for metal/inert-gas), is a semi-
automatic or automatic welding process with a continuously fed consumable wire acting as
both electrode and filler metal, along with an inert or semi-inert shielding gas flowed around
the wire to protect the weld site from contamination. Constant voltage, direct current power
source is most commonly used with GMAW, but constant current alternating current are used
as well. With continuously fed filler electrodes, GMAW offers relatively high welding
speeds, however the more complicated equipment reduces convenience and versatility in
comparison to the SMAW process. Originally developed for welding aluminium and other
non-ferrous materials in the 1940s, GMAW was soon economically applied to steels. Today,
GMAW is commonly used in industries such as the automobile industry for its quality,
versatility and speed. Because of the need to maintain a stable shroud of shielding gas around
the weld site, it can be problematic to use the GMAW process in areas of high air movement
such as outdoors.[9]

Flux-cored arc welding (FCAW) is a variation of the GMAW technique. FCAW wire is
actually a fine metal tube filled with powdered flux materials. An externally supplied
shielding gas is sometimes used, but often the flux itself is relied upon to generate the
necessary protection from the atmosphere. The process is widely used in construction
because of its high welding speed and portability.

Submerged arc welding (SAW) is a high-productivity welding process in which the arc is
struck beneath a covering layer of granular flux. This increases arc quality, since
contaminants in the atmosphere are blocked by the flux. The slag that forms on the weld
generally comes off by itself and, combined with the use of a continuous wire feed, the weld
deposition rate is high. Working conditions are much improved over other arc welding
processes since the flux hides the arc and no smoke is produced. The process is commonly
used in industry, especially for large products.[10] As the arc is not visible, it is typically
automated. SAW is only possible in the 1F (flat fillet), 2F (horizontal fillet), and 1G (flat
groove) positions.

Non-consumable electrode methods

Gas tungsten arc welding (GTAW), or tungsten/inert-gas (TIG) welding, is a manual welding
process that uses a non-consumable electrode made of tungsten, an inert or semi-inert gas
mixture, and a separate filler material. Especially useful for welding thin materials, this
method is characterized by a stable arc and high quality welds, but it requires significant
operator skill and can only be accomplished at relatively low speeds. It can be used on nearly
all weldable metals, though it is most often applied to stainless steel and light metals. It is
often used when quality welds are extremely important, such as in bicycle, aircraft and naval
applications.[11] A related process, plasma arc welding, also uses a tungsten electrode but uses
plasma gas to make the arc. The arc is more concentrated than the GTAW arc, making
transverse control more critical and thus generally restricting the technique to a mechanized
process. Because of its stable current, the method can be used on a wider range of material
thicknesses than can the GTAW process and is much faster. It can be applied to all of the
same materials as GTAW except magnesium; automated welding of stainless steel is one
important application of the process. A variation of the process is plasma cutting, an efficient
steel cutting process.[12]

Other arc welding processes include atomic hydrogen welding, carbon arc welding,
electroslag welding, electrogas welding, and stud arc welding.

Corrosion issues
Main articles: Hydrogen embrittlement and Galvanic corrosion

Some materials, notably high-strength steels, aluminium, and titanium alloys, are susceptible
to hydrogen embrittlement. If the electrodes used for welding contain traces of moisture, the
water decomposes in the heat of the arc and the liberated hydrogen enters the lattice of the
material, causing its brittleness. Stick electrodes for such materials, with special low-
hydrogen coating, are delivered in sealed moisture-proof packaging. New electrodes can be
used straight from the can, but when moisture absorption may be suspected, they have to be
dried by baking (usually at 450 to 550 °C or 840 to 1,020 °F) in a drying oven. Flux used has
to be kept dry as well.[13]

Some austenitic stainless steels and nickel-based alloys are prone to intergranular corrosion.
When subjected to temperatures around 700 °C (1,300 °F) for too long a time, chromium
reacts with carbon in the material, forming chromium carbide and depleting the crystal edges
of chromium, impairing their corrosion resistance in a process called sensitization. Such
sensitized steel undergoes corrosion in the areas near the welds where the temperature-time
was favorable for forming the carbide. This kind of corrosion is often termed weld decay.

Knifeline attack (KLA) is another kind of corrosion affecting welds, impacting steels
stabilized by niobium. Niobium and niobium carbide dissolves in steel at very high
temperatures. At some cooling regimes, niobium carbide does not precipitate, and the steel
then behaves like unstabilized steel, forming chromium carbide instead. This affects only a
thin zone several millimeters wide in the very vicinity of the weld, making it difficult to spot
and increasing the corrosion speed. Structures made of such steels have to be heated in a
whole to about 1,000 °C (1,830 °F), when the chromium carbide dissolves and niobium
carbide forms. The cooling rate after this treatment is not important.[14]

Filler metal (electrode material) improperly chosen for the environmental conditions can
make them corrosion-sensitive as well. There are also issues of galvanic corrosion if the
electrode composition is sufficiently dissimilar to the materials welded, or the materials are
dissimilar themselves. Even between different grades of nickel-based stainless steels,
corrosion of welded joints can be severe, despite that they rarely undergo galvanic corrosion
when mechanically joined.[15]

Safety issues

Welding safety checklist

Welding can be a dangerous and unhealthy practice without the proper precautions; however,
with the use of new technology and proper protection the risks of injury or death associated
with welding can be greatly reduced.

Heat, fire, and explosion hazard

Because many common welding procedures involve an open electric arc or flame, the risk of
burns from heat and sparks is significant. To prevent them, welders wear protective clothing
in the form of heavy leather gloves and protective long sleeve jackets to avoid exposure to
extreme heat, flames, and sparks. The use of compressed gases and flames in many welding
processes also pose an explosion and fire risk; some common precautions include limiting the
amount of oxygen in the air and keeping combustible materials away from the workplace.[16]
Eye damage

Auto darkening welding hood with 90×110 mm cartridge and 3.78×1.85 in viewing area

Exposure to the brightness of the weld area leads to a condition called arc eye in which
ultraviolet light causes inflammation of the cornea and can burn the retinas of the eyes.
Welding goggles and helmets with dark face plates—much darker than those in sunglasses or
oxy-fuel goggles—are worn to prevent this exposure. In recent years, new helmet models
have been produced featuring a face plate which automatically self-darkens electronically. [17]
To protect bystanders, transparent welding curtains often surround the welding area. These
curtains, made of a polyvinyl chloride plastic film, shield nearby workers from exposure to
the UV light from the electric arc.[18]

Inhaled matter

Welders are also often exposed to dangerous gases and particulate matter. Processes like flux-
cored arc welding and shielded metal arc welding produce smoke containing particles of
various types of oxides. The size of the particles in question tends to influence the toxicity of
the fumes, with smaller particles presenting a greater danger. Additionally, many processes
produce various gases (most commonly carbon dioxide and ozone, but others as well) that
can prove dangerous if ventilation is inadequate.
Drilling

Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in solid
materials. The drill bit is usually a rotary cutting tool, often multi-point. The bit
is pressed against the work-piece and rotated at rates from hundreds to thousands
of revolutions per minute. This forces the cutting edge against the work-piece, cutting
off chips (swarf) from the hole as it is drilled.

In rock drilling, the hole is usually not made through a circular cutting motion, though the bit
is usually rotated. Instead, the hole is usually made by hammering a drill bit into the hole
with quickly repeated short movements. The hammering action can be performed from
outside the hole (top-hammer drill) or within the hole (down-the-hole drill, DTH). Drills used
for horizontal drilling are called drifter drills.

In rare cases, specially-shaped bits are used to cut holes of non-circular cross-section;
a square cross-section is possible.
Drilled holes are characterized by their sharp edge on the entrance side and the presence
of burrs on the exit side (unless they have been removed). Also, the inside of the hole usually
has helical feed marks.[2]

Drilling may affect the mechanical properties of the workpiece by creating low residual
stresses around the hole opening and a very thin layer of highly stressed and disturbed
material on the newly formed surface. This causes the workpiece to become more susceptible
to corrosion and crack propagation at the stressed surface. A finish operation may be done to
avoid these detrimental conditions.

For fluted drill bits, any chips are removed via the flutes. Chips may form long spirals or
small flakes, depending on the material, and process parameters. [2] The type of chips formed
can be an indicator of the machinability of the material, with long chips suggesting good
material machinability.

When possible drilled holes should be located perpendicular to the workpiece surface. This
minimizes the drill bit's tendency to "walk", that is, to be deflected from the intended center-
line of the bore, causing the hole to be misplaced. The higher the length-to-diameter ratio of
the drill bit, the greater the tendency to walk. The tendency to walk is also preempted in
various other ways, which include:

 Establishing a centering mark or feature before drilling, such as by:

o Casting, molding, or forging a mark into the workpiece
o Center punching
o Spot drilling (i.e., center drilling)
o Spot facing, which is machining a certain area on a casting or forging to establish an
accurately located face on an otherwise rough surface.
 Constraining the position of the drill bit using a drill jig with drill bushings

Surface finish produced by drilling may range from 32 to 500 microinches. Finish cuts will
generate surfaces near 32 microinches, and roughing will be near 500 microinches.

Cutting fluid is commonly used to cool the drill bit, increase tool life, increase speeds and
feeds, increase the surface finish, and aid in ejecting chips. Application of these fluids is
usually done by flooding the workpiece with coolant and lubricant or by applying a spray
mist.[2]
In deciding which drill(s) to use it is important to consider the task at hand and evaluate
which drill would best accomplish the task. There are a variety of drill styles that each serve a
different purpose. The subland drill is capable of drilling more than one diameter. The spade
drill is used to drill larger hole sizes. The indexable drill is useful in managing chips.

Cutting

Cutting is the separation or opening of a physical object, into two or more portions, through
the application of an acutely directed force.

Implements commonly used for cutting are the knife and saw, or in medicine and science

the scalpel and microtome. However, any sufficiently sharp object is capable of cutting if it
has a hardness sufficiently larger than the object being cut, and if it is applied with sufficient
force. Even liquids can be used to cut things when applied with sufficient force (see water jet
cutter).

Cutting is a compressive and shearing phenomenon, and occurs only when the

total stress generated by the cutting implement exceeds the ultimate strength of the material
of the object being cut. The simplest applicable equation is:

 or 

The stress generated by a cutting implement is directly proportional to the force with which it
is applied, and inversely proportional to the area of contact. [1] Hence, the smaller the area
(i.e., the sharper the cutting implement), the less force is needed to cut something. It is
generally seen that cutting edges are thinner for cutting soft materials and thicker for harder
materials. This progression is seen from kitchen knife, to cleaver, to axe, and is a balance
between the easy cutting action of a thin blade vs strength and edge durability of a thicker
blade.

Cutting has been at the core of manufacturing throughout history. For metals many methods
are used and can be grouped by the physical phenomenon used. It is the process of producing
a work piece by removing unwanted material from a block of metal, in the form of chips.

 Chip forming (material removal processes) – sawing, drilling, milling, turning etc.

 Shearing – punching, stamping, scissoring, blanking
 Abrasive material removal – grinding, lapping, polishing, water-jet
 Heat – flame cutting, plasma cutting, laser cutting
 Electrochemical – etching, electrical discharge machining (EDM), electrical chemical
machining (ECM)

Every method has its limitations in accuracy, cost, and effect on the material. For example,
heat may damage the quality of heat treated alloys, and laser cutting is less suitable for highly
reflective materials such as aluminum.[2] Laser cutting sheet metal produces flat parts and
etches and engraves parts from complex or simple designs. It is used over other cutting
options for its quick process and customizable abilities.

Grinding
Grinding is an abrasive machining process that uses a grinding wheel as the cutting tool.

A wide variety of machines are used for grinding:

 Hand-cranked knife-sharpening stones (grindstones)

 Handheld power tools such as angle grinders and die grinders
 Various kinds of expensive industrial machine tools called grinding machines
 Bench grinders

Grinding practice is a large and diverse area of manufacturing and toolmaking. It can produce

very fine finishes and very accurate dimensions; yet in mass production contexts it can also
rough out large volumes of metal quite rapidly. It is usually better suited to the machining of
very hard materials than is "regular" machining (that is, cutting larger chips with cutting tools
such as tool bits or milling cutters), and until recent decades it was the only practical way to
machine such materials as hardened steels. Compared to "regular" machining, it is usually
better suited to taking very shallow cuts, such as reducing a shaft's diameter by half
a thousandth of an inch or 12.7 μm.

Grinding is a subset of cutting, as grinding is a true metal-cutting process. Each grain of

abrasive functions as a microscopic single-point cutting edge (although of high negative rake
angle), and shears a tiny chip that is analogous to what would conventionally be called a
"cut" chip (turning, milling, drilling, tapping, etc.) [citation needed]. However, among people who
work in the machining fields, the term cutting is often understood to refer to the macroscopic
cutting operations, and grinding is often mentally categorized as a "separate" process. This is
why the terms are usually used separately in shop-floor practice.

Lapping and sanding are subsets of grinding.

Design of machine

DESIGN OF THE MACHINE

1 General Requirements of Machine Design

1. High productivity.
2. Ability to produce and provide required accuracy of shape and size and also necessary
surface finish.
3. Simplicity of design.
4. Safety and convenience of control
5. Low Cost.
6. Good Appearance.
7.
8.2 Design Procedure

Before we proceed to the process of manufacturing, it’s necessary to have some

knowledge about the project design essential to design the project before starting the
manufacturing. Maximum cost of producing a part of product is established originally by the
designer.

The product consists of:

1. FUNCTIONAL DESIGN.
2. PRODUCT DESIGN.
3. ENGINEERING DESIGN.

8.3 Design procedure for a product:

 When a new product or their elements are to be designed, a designer may proceed as
follows:

1. Make a detailed statement of the problems completely; it should be as clear as possible &
also of the purpose for which the machine is to be designed

2. Make selection of the possible mechanism which will give the desire motion.

3. Determine the forces acting on it and energy transmitted by each element of the Machine

4. Select the material best suited for each element of the machine.

5. Determine the allowable or design stress considering all the factors that affect the Strength
of the machine part.

6. Identify the importance and necessary and application of the machine.

7 Problems with existing requirement of the machine productivity and demand

8. Determine the size of each element with a view to prevent undue distortion or breakage
under the applied load.

9. Modify the machine element or parts to agree with the past experience and judgment and
to facilitate manufacture.

10. Make assembly and detail drawings of machine with complete specification for the
materials and manufacturing methods i.e. accuracy, Surface finish etc

Cost estiation

Sr.No. Perticulars Qyantity price

1 Wiper Motor 1 2500
5 1.5x1.5 MS square pipe 2 2000
6 2x2 Ms square pipe 1 500
7 6204 UPC bearing 1 350
8 20mm dia round bar 1 500
9 6204 ball bearing 4 280
10 Carbide plate cutter 8 400
11 50x5 Ms plate 1 400
 12 Circular plate 10mm thick 6 inch round 1 300
13 Other 1000
14 Fabrication 4000
TOTAL 12720

ADVANTAGES & LIMITATION

– Simple in construction.

– Initial cost is low.

– Less man power.

– Easy to maintain.

– Save large amount of sugarcane bud from waste by plant in form.

– We get more sugarcane compare than normal sugarcane plant method.

– Easy to operate.

– Saved sugarcane are used to white sugar production and juice.

Future scope

By putting little bit automation in machine we can make this machine fully automated.such as
we can use motor driver to control speed. We can use plc controller. Also buy putting sensor
in cutting zone we get motion only if there is an object to cut else where machine can not
start means motor can not rotate.

Conclusion

By doing this project sucessfully make a machine which cut sugarcane 4 bud at a
time.

We also learn importance of team work and what are difficulties come during manufacturing
and during assembling process. We learn about induction motor working and reduction
gearbox .
 Our machine is very simple in construction and having zero maintainance.also any
unskilled worker can operate this. This is very user friendly machine with mediun astetic look
and ergonomic consideration.

References

[1] Abel Roy J, Gat Vaibhav D, Patel Harshavardhan,Upadhye Dhiraj D, Students Under the
guidance of Kiran P.Asst. Professor, “Design and Fabrication of Semi-automated Sugarcane
Bud Chipper” FIESTA-16 A National Level Conference and Technical Fest on 30th April
2016.

[2] Balakrishnan, N, Mayilsamy, K 2014, ‘Effect of compression ratio on CI engine

performance with biodiesel and producer gas in mixed fuel mode’, Journal of Renewable and
Sustainable Energy, vol.6, pp. 0231031-02310313. ISSN: 1941-7012.

[3] F. Dirksena, M. Anselmanna, T.I. Zohdi, R. Lammering, “Incorporation of flexural hinge

fatigue-life cycle criteria into the topological design of compliant small-scale devices,”
Precision Engineering, vol. 37, pp.531–541, 2013.

[4] Mandla S. Mnisiand Cliff S. Dlamini, “The concept of sustainable sugarcane production”,
Global, African and South African perceptions,(Vol. 7(31), pp. 4337-4343,14 August, 2012.

[5] Ningappa H Kurri, Prof. Reddy Naik.J, “Design and Development of Sugar Cane Bud
Chipping Machine” International journal of research in aeronautical and mechanical
engineering ISSN (online): 2321-3051 vol.3 issue 12, December 2015pgs: 97-110.

[6] Katarina Monkova, Peter Monkova, “Kinematic analysis of quick-return mechanism in

three various approaches” technical gazette 18, 2(2011).

[7] Sanjay Patil Sir, Nikhil Nangare, Aditya Waghmare, Mayur Zope, Meet Thakker)
“Design And Modification of Sugarcane Bud Scooping Machine”, International Research
Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056 Volume: 03 Issue: 04
April-2016 ISSN: 2395-0072.

[8] R.Moses Samuel, Saravanan S,R.Rathish, Dr.N.Balakrishnan, C.Venkatramanan,

M.Vignesh,M,Vijay, ‘Design and Fabrication of Bicycle Using Four Bar Mechanism’,
International Journal of Scientific Research in Science,Engineering and Technology, Vol.3,
pp. 611- 614, Issue 2, April 2017, ISSN: 2395-1990.
[9].Rishi Anand,Khomesh,Shrawan Kumar,Prof. Alok Verma,” Theoretical Analysis Of Four
Way Blade Machine”, International Journal of Advance Research and Innovative Ideas in
Education, ISSN(O)-2395-4396, Vol-2 ,Issue-2 ,April2016

[10]. Prof. Nitinchandra R. Patel, Mohammad A. Vasanwala, Balkrushna B.Jani,

Miteshkumar D. Rathwa, Ravi A. Thakkar,” Material Selection and Testing of Blade Based
on Mechanical properties”, International Journal of Innovative Research in Science,
Engineering and Technology, ISSN: 2319-8753, volume 2, Issue6, June 2013.

[11]. D.V.Sabarinanda, V.Siddhartha, B. Sushil Krishnana, T.Mohanraj , “Design and

Fabrication of Automated Machine”, International Journal of Innovative Research in
Science, Engineering and Tech nology, ISSN (Online):2319-8753, volume 3, April 2014.

[12]. Rakesh Ambade,Amit Sartabe,Meghraj Arekar,Vaibhav Khachane,Prajakta Gawali ,”

Design & Fabrication of Multi-Purpose Machine”, International Journal of Advanced
Technology in Engine ering and Science,ISSN(Online):2348-7550,Volume No 03,Special
Issue No.01,April 2015.

[13]. Kshirsagar Prashant R, Rathod Nayan,Rahate Prashant P,Halaye Prashant

P ,”Theoretical Analysis of Multi-way Power Machine”,International Journal of Research in
Advent Technology,E-ISSN:2321- 9637,Vol.3,No.4,April2015

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