Design of Sugar Cane Machine

[DESIGN OF SUGARCANE JUICE EXTRACTION MACHINE]
By
Nahom Tadesse 0970/06
Mihret Tegenu 0800/08
Rediet Zeleke 0933/08
A Thesis Submited in Partial Fulfillment
of the Requirments for the Degree of
Bachler of Science
in Mechanical Engineering
Thesis advisor:
Walelign molla
(Lecturer, Mechanical Engineering Department )
DEPARTMENT OF MECHANICAL ENGINNERING
COLLEGE OF ELECTRICAL AND MECHANICAL ENGINEERING
ADDIS ABABA SCIENCE AND TECHNOLOGY UNIVERSITY

ADDIS ABABA ETHIOPIA
JANUARY, 2021
Design of sugarcane juice extraction machine
ADDIS ABABA SCIENCE AND TECHNOLOGY UNIVERSITY
COLLEGE OF ELECTRICAL AND MECHANICAL ENGINEERING
MECHANICAL ENGINNERING DEPARTMENT
[Design of Sugarcane Juice Extraction Machine ]
Submitted by: Signature Date
Approved by Signature Date
ii
DECLARATION
We hereby declare that the work which is presented in this thesis entitled
“[DESIGN OF SUGARCANE JUICE EXTRACTION MACHINE] original
work of our own, has not been presented for a degree of any other university and
that all sources of material used for the thesis have been duly acknowledged.
Submitted by: Signature Date
iii
ACKNOWLEDGEMENT
First of all, we would like to thank the almighty God for the courage he gave us to
accomplish this project after all this hard time. We are very thankful for the continuous
encouragement in the valuable supervision, timely suggestion and inspired guidance
offered by our advisor Walelign Molla. Lastly, we would like to thank all our families and
friends for their support and valuable suggestion.
iv
ABSTRACT
This project deals with design of automatic sugarcane juice extraction machine that can be
used in our home, cafes, juice shop, local farmer of sugarcane and peoples who sell
sugarcane on street. Due to the richness of sugar cane juice with different minerals it has
so many health benefits. The machine extract juice from the cane by squeezing the sugar
cane between three crushing rollers. It contains three main components which are crushing
unit, power source and power transmission unit. The crushing unit includes a roller to
squeeze the cane and extract the juice. Power source used to run the machine by a DC
motor and by means of power transmission unit like key, shaft, gear, pulley and V-belt.
These machines are not widely known in our country and also, it has been noticed some
problem in existing machine it includes direct subjection of hand to the rotating part and
corrosion of machine motivate us to design the machine and manufacture of sugarcane
juice extraction machine with a better safety, corrosion resistant material, and flexible and
unique design. So, we select proper material for each component and design a machine
with a medium and compact size by minimizing the cost. The cost to manufacture the
machine is minimized by 50% of the purchased one.
v
Table of Contents
ACKNOWLEDGEMENT ................................................................................................. iv
ABSTRACT........................................................................................................................ v
LIST OF TABLES ............................................................................................................. ix
CHAPTER ONE ................................................................................................................. 1
1. BACKGROUND AND OVERVIEW ............................................................................ 1
1.1. Introduction ............................................................................................................. 1
1.1.1 Components of machine .................................................................................... 3
1.2 Statement of the problem .......................................................................................... 4
1.3 Objectives ................................................................................................................. 5
1.3.1 General objective ............................................................................................... 5
1.3.2 Specific objective ............................................................................................... 5
1.4 Significance of the study ........................................................................................... 5
1.5 Scope of the project .................................................................................................. 6
CHAPTER TWO ................................................................................................................ 7
2. LITERATURE REVIEW ............................................................................................... 7
CHAPTER THREE .......................................................................................................... 10
3. METHODOLOGY ....................................................................................................... 10
3.1 Overview ................................................................................................................. 10
3.2 Method .................................................................................................................... 12
CHAPTER FOUR ............................................................................................................. 13
4. DETAIL DESIGN ........................................................................................................ 13
4.1 MATERIAL SELECTION ..................................................................................... 13
4.1.1 Selection of material for roller ......................................................................... 14
4.1.2 Material selection for shafts ............................................................................. 17
4.1.3. Material selection for the cover ...................................................................... 18
4.1.4. Material selection for bolt and frame .............................................................. 19
4.1.5. Material selection for key ............................................................................... 20
4.1.6 Selection for power transmission ..................................................................... 22
4.1.7 Selection of gear type for gearbox ................................................................... 23
4.1.8 Selection of bearing type ................................................................................. 24
4.2 Design calculation ................................................................................................... 25
vi
4.2.1 Design of roller ................................................................................................ 25

4.2.2 Selection of motor ............................................................................................ 28
4.2.3 Design of pulley and V-belt ............................................................................. 29
4.2.4 Design of shaft diameter .................................................................................. 32
4.2.5 Design of key ................................................................................................... 34
4.2.6 Design of bolt ................................................................................................... 35
4.2.7 Design of gear .................................................................................................. 36
4.2.8 Bearing selection .............................................................................................. 40
4.2.9 Design of frame................................................................................................ 40
4.2.10 Stress analysis of roller .................................................................................. 41
4.4 Working principle ................................................................................................... 46
CHAPTER FIVE .............................................................................................................. 48
5. MANUFACTURING AND ASSEMBLY METHOD ................................................. 48
5.1 Manufacturing method ............................................................................................ 48
5.1.1 Manufacturing of roller .................................................................................... 48
5.1.2 Manufacturing of shaft ..................................................................................... 49
5.1.3 Manufacturing of key ....................................................................................... 50
5.1.4 Manufacturing of spur gear .............................................................................. 50
5.1.5 Manufacturing of frame and cover .................................................................. 51
5.1.6 Manufacturing of bolt and nuts ........................................................................ 51
5.1.7 Manufacturing of bearing ................................................................................ 52
5.1.8 Manufacturing of pulley .................................................................................. 52
5.2 Assembly method.................................................................................................... 52
5.3 Maintenance of the machine ................................................................................... 53
5.3.1 Maintenance of roller ....................................................................................... 53
5.3.2 Maintenance of spur gearbox ........................................................................... 53
5.1.3 Maintenance of V-belts and pulley .................................................................. 54
5.1.4 Maintenance of Pulley ..................................................................................... 54
5.1.5 Maintenance of belt.......................................................................................... 54
5.1.6 Maintenance of bearing.................................................................................... 55
CHAPTER SIX ................................................................................................................. 57
6.COST ANALYSIS......................................................................................................... 57
vii
6.1 Cost analysis ........................................................................................................... 57

CHAPTER SEVEN .......................................................................................................... 61
7. RESULT AND DISCUSSION ..................................................................................... 61
7.1 Result ...................................................................................................................... 61
7.2 Discussion ............................................................................................................... 62
CHAPTER EIGHT ........................................................................................................... 65
8. CONCLUSION AND RECOMMENDATION ............................................................ 65
8.1 Conclusion .............................................................................................................. 65
8.2 Recommendation .................................................................................................... 65
REFERENCE .................................................................................................................... 66
APPENDIX ....................................................................................................................... 68
viii
LIST OF TABLES
Table 4. 1 Properties of materials used for the design of roller ........................................ 14
Table 4. 2 Weight of properties used for the design of roller. .......................................... 15
Table 4. 3 Comparison of materials used for the design of roller..................................... 16
Table 4. 4 Properties of materials used for the design of the shaft .................................. 17
Table 4. 5 Comparison of materials used for the design of the shaft................................ 18
Table 4. 6 Properties of material used for the design of the cover .................................. 18
Table 4. 7 Comparison of materials used for the design of the cover .............................. 19
Table 4. 8 Properties of material used for the design of the frame ................................... 19
Table 4. 9 Comparison of materials used for the design of the frame and bolt ............... 20
Table 4. 10 Weightage of points for comparison of keys ................................................. 21
Table 4. 11 Comparison of saddle key and sunk key ....................................................... 21
Table 4. 12 Selection of power transmission method ....................................................... 22
Table 4. 13 Comparison of the spur gear and helical gear............................................... 23
Table 4. 14 Weightage of points used to select gear......................................................... 23
Table 4. 15 Selection of gear for sugar cane machine ...................................................... 24
Table 4. 16 Weightage of points used to select bearing ................................................... 24
Table 4. 17 Comparison of different types of bearing ..................................................... 25
Table 4. 18 Measured value of different size sugar cane ................................................. 26
Table 4. 19 Comparison of dc motors ............................................................................... 29
Table 5. 1 Maintenance of sugarcane extraction machine……………………………….55
Table 6. 1 Cost analysis of the sugarcane juice extractor………………………………...60
Table 7. 1 Result of crushing roller………………………………………………………61
Table 7. 2 Results of pulley and V-belt ............................................................................ 61
Table 7. 3 Result of shaft and key..................................................................................... 62
Table 7. 4 Result of spur gear ........................................................................................... 62
Table 7. 5 Result of bearing .............................................................................................. 62
Table 7. 6 Result of maximum shear stress values of roller ............................................. 62
ix
CHAPTER ONE
1. BACKGROUND AND OVERVIEW
1.1. Introduction
Sugarcane is a tropical, perennial grass categorized to large, long term grasses and forms
lateral shoots at the base to produce multiple stems, typically 3 to 4 m (10 to 13 ft) high
and about 5 cm (2 in) in diameter. The stems grow into cane stalk which, when mature,
constitutes around 75% of the entire plant. A mature stalk is typically composed of 11–
16% fiber, 12–16% soluble sugars, 2–3% non-sugars, and 63–73% water [1].
Sugarcane crop is native to warm temperature, it is widely grown in tropical and sub-
tropical regions of the world. Statistics shows world areas where sugar cane produce vastly
are Southeast Asia, the Indian Subcontinent, North Africa, and Latin America and also it
is produced in our country mostly in the east and northern part of Ethiopia mainly for the
production of sugar [2].
The main product of sugarcane is sucrose, which accumulates in the stalk internodes.
Sucrose, extracted and purified in specialized mill factories, is used as raw material in
human food industries or is fermented to produce ethanol, a low pollution fuel. Other than
sugar, products derived from sugarcane include falernum, molasses, rum, cachaça, bagasse,
ethanol, and sugarcane juice. In some regions, people use sugarcane reeds to make pens,
mats, screens, and thatch [3].
Sugarcane juice is the liquid extracted from pressed sugarcane. It is used as a sweetener in
food and beverage manufacturing in many places [4]. Sugar cane juice has several health
benefits and medicinal properties most of which remain unknown to the masses. The
sugarcane juice extracted from healthy canes has high medicinal value. Medical researches
show its medicinal properties get enhanced when mixed with juices of lemon and ginger
[5].
Nutritionally, sugarcane juice has no simple sugar. Sugarcane juice is a mild laxative too
due to its high potassium, iron, and calcium content. The juice extracted from sugarcane
strengthens the body by providing several nutrients. It includes Magnesium – 2.5 mg,
Calcium – 32.57 mg, Fats – 0.09 g, Water – 0.19 g, Ash – 0.66 g, Carbohydrates – 27.40
1
g, Protein – 0.20 g, and Calories – 111. It is also containing iron and vitamins A, C, B1,
B2, B3, B5, and B6, plus a high concentration of phytonutrients (including chlorophyll),
antioxidants, proteins, soluble fiber, and numerous other health-supportive components
[6].
Due to its richness with different minerals, it is useful to prevent cancer from occurring,
for normal functioning of the kidney, act as an energy booster, it can keep the skin hydrated
and prevents aging, helps to lose weight, prevent tooth decay. Sugarcane also acts as a
substitute for soft drinks or aerated drinks for diabetic patients, It facilitates safer pregnancy
and quicker conceptions.
However, in some cases, it can be a health risk due to its unhygienic condition under which
it is prepared in some countries with lower health standards. Some diseases can be
transmitted by raw sugar-cane, such as Leptospirosis.[7]
In the ancient period the juice from sugarcane is extracted by using mortar and pestle
arrangement operation press by human power, then by animals or water power, and screw
press. These were widely used for juice extraction until it was taken over by roller mills
which were invented by a cane grower in Sicily in 1449[8].
The juice is extracted by crushing the sugarcane between two or more rollers and one
feeding crusher after they have been stripped of leaves and cut into suitable lengths. By
this means, most of the juice is extracted then the residual passes through a collector and
is further compressed by a presser to remove the remaining juice [8].
Now days Sugarcane juice is extracted by different machines that are available in the
market and these are classified into sugarcane machine, sugarcane standing machine,
tabletop sugarcane machine, automatic sugarcane extractor, commercial sugarcane
machine, manual sugarcane extractor, heavy-duty sugarcane machine, sugarcane juicer,
Industrial sugarcane machine, stainless steel sugarcane crusher, domestic sugarcane
machine [9].
In our project we will design a sugar cane machine that has three rollers namely top roller,
feeding roller, and discharge roller. The main purpose of this paper is to improve some of
the designs of the machines and increase their usability. The design improvement includes:
- the introduction of a handle to move it from place to place, rubber legs to dump the
unnecessary vibration caused by the motor, a filter is included with the juice discharge unit
2
to avoid inclusion of bagasse to the juice, also the frame is made of metal sheet that has
enough openings to allow easily cooling of the motor.
1.1.1 Components of machine
A sugar cane juice extractor is a machine that can extract juice by squeezing and grinding
the hard sugar cane pulp. The machine might be manually driven by human power or
automatically driven by an electrical motor. In recent years, the manual machine becomes
obsolete and replaced by the automatic one since it is not efficient and time-consuming.
The electrical machine is made up of different systems which collectively give its efficient
function. Those are: -
1. Crushing unit
The main parts of the machine are used to crush the cane and squeeze the juice from the
raw cane. The crushing unit has3 rollers called the top, feeding, and discharge rollers. All
three rollers have the same structure and size. The three rollers have a knurling like
structure on their face to increase the surface roughness for easy gripping of sugarcane.
Both the feeding and discharge rollers always rotate in the same direction. However, the
top roller rotates opposite to the rest of the two.
2. Power source
The machine works automatically driven by an electric motor. An electric motor is a
machine that converts electrical energy into mechanical energy. It operates through the
interaction between the motor's magnetic field and electric current in a wire winding to
generate force in the form of torque applied on the motor's shaft.
3. Power transmission unit
The power transmission unit is used to transfer energy from where its generated to a place
where it is used to perform work (from the motor to the crushing unit). Rotational power
is produced by the motor transmitted through a series of belt, gears, shafts, pulleys, and
keys to perform its work.
A shaft is a mechanical power transmission unit having a circular cross-section used to
transmit the rotational power of the motor to the crushing unit and also it is used to mount
another power transmission unit such as gears, belts, pulleys, and keys.
3
Gears are rotating circular machine part having cut teeth which mesh with another gear or
toothed part to transmit torque. They are considered a simple machine because different
size gears can produce a change in torque and speed through their gear ratio.
Pulleys are the wheel that carries a flexible rope, cord, cable, chain, or belt on its rim. They
are used singly or in combination to transmit energy and motion.
v-belt is a loop of flexible material used to link two or more rotating shafts mechanically
most often parallel. They may be used as a source of motion, to transmit power efficiently,
or to track relative movement. Belts are looped over pulleys and may have a twist between
the pulleys and the shafts need not be parallel.
keys are a piece of mild steel inserted between the shaft and hub or boss of the pulley to
connect these to prevent relative motion between them. It is always inserted parallel to the
axis of the shaft. Keys are used as temporary fastenings and are subjected to considerable
crushing and shearing stresses. A keyway is a slot or recess in a shaft and hub of the pulley
to accommodate a key.
4. Body
Body or frame is used to prevent the intrusion of dust material and to prevent the occurrence
of hand injuries. A wide variety of mechanical motions and actions may present hazards to
the worker. These can include the movement of rotating members, moving belts, meshing
gears, and any parts that impact or shear.
Power transmission apparatus which transmits energy to the part of the machine
performing the work including pulleys, belts and gears and other moving parts which move
while the machine is working including rotating and transverse moving parts, as well as
feed mechanisms and auxiliary parts of the machine require safeguarding.
Additionally, it improves the aesthetics of the machine by balancing color, movement,
pattern, scale, shape, and visual weight.
1.2 Statement of the problem

In Ethiopia, sugar cane juice extraction machine is not widely known so sugar cane is
consumed traditionally by the employment of teeth in biting off the rind and chewing up
the internal tissues then suck the juice and spat out the bagasse. This method of
consumption doesn’t allow to gain the juice efficiently, consumes a lot of time and energy,
4
put the human teeth in duress, soil the hands and clothing of the consumer, hard to be
consumed by elders and children.
Most juice extraction machine that is used to simplify the method of consumption have
also their problem due to direct subjection of rotating parts to the person operating the
machine so the probability of occurring accidents like hand injuries is high.
Since the juice is liquid, it has a good amount of moisture in it; which would enhance the
corrosion of the mild steel frame. The juice tends to cause different disease due to the
existence of rust and surrounding debris into the extraction process of the fabricated
machine and introduced into the desired substance get to a mix-up with it and when
consumed, they tend to reside in the body and accumulate until its adverse effect would be
prominent.
The sugarcane juice extractor machine is not manufactured in our country so they are
imported from a foreign country due to this factor the cost of the machine is high. This
limits the usage of the machine in our country.
1.3 Objectives
1.3.1 General objective
The main objective of the project is design and development of animation of a sugar cane
juice extracting machine.
1.3.2 Specific objective
To take an assumption and basic consideration for the design parameters.
To select materials based on standard criteria.
To design parts of the machine.
To prepare part and assembly drawing.
To develop an animation that shows how the machine work.
1.4 Significance of the study

Since the technology is not widely familiar in our country designing and manufacturing
simple sugarcane juice extraction machines will minimize time losses and product losses
due to the old method and also it will upgrade the way of cane consumption and promotes
healthier nutrition that has so many advantages to the society.
5
The machine will create a safe environment for the operators by avoiding direct contact
with the moving parts by the inclusion of cover on the feeding and waste removal unit. So,
the major safety problem of hand injuries will be solved.
The construction of the casing from high wear-resistant material reduces the intrusion of
rust in the extracted juice so the hygiene of the machine would be improved since the
presence of contaminants such as rust would be solved.
Manufacturing of the machine in our country increases the availability of the machine and
also its cost is minimized. These will offer a great contribution to the country by reducing
foreign currency and creating job opportunities.
1.5 Scope of the project

Designing different parts of sugar cane extracting machines such as rollers, gears, shaft,
and frame.
Preparing a CAD model by using SolidWorks application to present the part drawing and
an assembly drawing.
Development of an animation to show the working method of the machine.
6
CHAPTER TWO
2. LITERATURE REVIEW
(MAKINDE-OJO, 2010) perform research on the improvement of sugar cane juice
extractor machine by constructing casing for the operating chamber. This helps to shield
off the intrusion of rust in the extracted juice. Furthermore, the casing would improve the
safety of the operator. This is ensured by the covering of the moving parts such as the gears.
Also, the aesthetics and the hygiene of the machine is improved since the presence of
contaminants such as rust would be curbed. Besides, due to the adoption of the hopper
section, the number of sugarcane pieces and cutting that can be handled at the same time
would be improved thus saving time losses and the activity of the employed labor [10].
(Olaoye, 2011) developed a sugarcane juice extractor for small scale industries. The design
is a simple mechanical device for the extraction of sugarcane juice. The output capacities
of 10.50, 12.00, and 14.25 kg/hr were obtained at operating speeds of 0.25, 0.3, and 0.36
m/s. The extraction efficiency of the machine ranged between 40 and 61 % at operating
speeds of 0.25 and 0.36 m/s. but he can able to observe that this optimum performance of
the machine cannot be sustained over a long processing period due to the bluntness
development of the perforated grating drum over time [11].
(Olaniyan & Babatunde, 2012) designed a small-scale sugarcane juice extractor using a
screw pressing system mainly intended for the techno-economic status of the micro and
small-scale sugarcane farmers and juice processors. The machine is portable and it avoids
technical complexity to be easily maintained by small scale farmers in rural communities.
The juice yield and extraction efficiency are improved to 2.5 % and 87.8 % respectively
by improvement in the design, analysis, and optimization of the worm shaft and press cage
[12].
(Rumah & Mohammed, 2015) designed sugar cane juice extractor that has short stainless-
steel removable rollers. The juice extractor includes a housing with three compartments,
the first for extracting the juice and contains the crushing rollers; the third contains the
main drive, while the second serves as re-enforcement for the connecting shafts. The first
compartment is a closure for accessing the compartment; the closure is preferably a clear
plate that permits viewing the compartment during operation and, when removed, allows
7
access to the compartment for removal of the crushing rollers and cleaning of the rollers
and the compartment. Also, a safety switch is provided to prevent rotation of the rollers
when the closure is displaced to prevent injury. A guide into the compartment is provided
to direct the sugar cane and any flavorings into the crushing rollers. A waste channel is
provided for the exit of the bagasse [13].
(Piacente et al., 2016) a classic crushing mill operates three grooved rollers, two installed
on the same plane lower than the third. The purpose of this triangular arrangement is to
enable the raw material to be squeezed twice. In the three cylinders, one may have two
grinding rolls, one for power and other pressure (pressure-roller and top-roller). The
extraction operation is to pass the rod through the grinding bed between the rollers resulting
in the extraction of the broth which seeps between the grooves of the rollers. During this
passage, the water is added to the bagasse to dilute the stock and facilitate the process. The
described set of three main cylinders and two optional supports is called a milling suit [14].
(Priya & Lakshmi, 2018) designed instant cooling sugarcane juice machine. On their
design, they mainly studied problems faced by the vendors during the extraction of
sugarcane juice manually. According to the study, vendors faced pain in their body parts
viz., shoulders, wrist, arms, and neck due to the improper height of the workstations on
which they are working. So, they increase the height of the workstation, providing a waste
bin at the reachable height, providing a flip to the machine so that the injuries can be
avoided during the juice extraction. Also, the machine has instant cooling and no need for
large space to establish this unit, easy to operate, easy to clean, noiseless construction, a
body constructed from stainless steel, runs on1H.V. motor, and have an inbuilt compressor
[9].
(Ambare et al., 2019) design and manufacture a machine that can extract sugarcane juice
automatically with maximum juice extraction efficiency. From 1kg of sugarcane,
approximately 300ml of juice can be extracted to get this amount of juice more pressure
should be applied to the cane. but sometimes the motor will not supply sufficient torque so
the cane is stuck in between rollers and increase the chance of failure to the machine. So,
to decrease the failure of the machine and to reduce human involvement to prevent injury
to the operator they have added one more roller to the existing machine which will also
help to extract maximum juice [8].
8
(Raji et al., 2019) design a machine that consists of the 2.0-hp gear motor and crush
mechanism of the machine, consisting of gears, latches, and three rollers which have then
been mounted with the juicer and inlet and outlet on the frame. The crushing unit consists
of three rollers, one big roller, and two tiny rollers. The top-mounted roller controls the
movement of two bottom-mounted rollers. The two other rollers move at the same speed
as the top roller shaft but in opposite direction. The transmission is carried through the gear
motor to two more rollers. The machine has appropriate disposal for the bagasse and can
be used in a closed room. It also has a unique design that is quiet during operation as well
as compact with the ability to squeezes any sugar cane of a diameter of less than 52 mm.
The interaction between contaminants and the extracted juice is considered negligible with
the supplied isolation of the extraction process from the environment and due to the electric
transmission motor used, the rollers work without being stuck independent of the sugar
cane juice [15].
(Ugye & Kolade, 2019) design and construct a portable and cost-effective juice extraction
machine that can be affordable to both farmer individuals and local industries. The machine
has an approximate height of 805mm, a length of 511.3mm, and a breath of 459.96mm.
The materials used in the construction of the machine are mild steel (low carbon steel)-
because of its malleability, ductility, and plasticity properties. Stainless steel-Used as
bearing material because of its ductility. Cast iron is used for the manufacture of the pulley
since it can be machined and for its cheapness [16].
9
CHAPTER THREE
3. METHODOLOGY
3.1 Overview
The compilation of this project contains 8 chapters that are interrelated to one another. The
first two chapters (i.e., introduction and literature review part) used to give enough
information about the previous machines about their strength, their limitation, and which
gaps are solved by our project. In the 3rd chapter organization of the project and methods,
we have used for the design are clearly stated. The 4th chapter (i.e., detail design) is the
main part of the project used to determine the dimensions of each component and their
reaction under the application of load by selecting suitable material based on different
criteria. The 5th and 6th chapter shows how each part could be manufactured their assembly
method and cost for the manufacturing of the machine. Finally, the last two chapters state
all the result found from the design and cost analysis and discuss whether they met our
objective or not and further recommendation used for modification of the machine is stated.
The methodology used for the project is stated on the above flow chart.
10
11
3.2 Method
In this project, we develop a computer-aided design by using the SolidWorks application.
The application is used for 3 purposes. The first one is to design 2D and 3D drawings for
each part and the assembly drawing. The second one is to animate the machine helps to
illustrate the working mechanism of the machine. The last one is to create an exploded
view that shows the assembly and disassembly of the machine.
12
CHAPTER FOUR
4. DETAIL DESIGN
4.1 MATERIAL SELECTION
The sugar cane juice extractor machine has different parts that are assembled to give the
required function. These parts have to be made of a suitable material to perform the given
application efficiently. The selection of proper material for the machine component is one
of the most important steps in the process of machine design. The proper material for each
part is selected by using different material selection method. There are different factors
which should be considered while selecting a material for the machine component this
includes availability, cost, mechanical properties, physical properties, and manufacturing
consideration. Mechanical properties are the most important technical factor governing the
selection of material. Using the listed factors especially by giving more attention to
mechanical property and cost appropriate material will be selected for our machine
components. Since the machine needs to give effective purpose with minimum price.
Materials used for the sugarcane juice extraction machine should have the following core
properties:
• Strength: material can resist stress without rupture due to external forces.
• Stiffness or rigidity: the material can resist deformation under the action of an
external load.
• Wear resistance: the ability of a material to resist a gradual reduction of the size of
parts and a change in the shape of the machine along with various surfaces due to
friction. The wear resistance of a material is related to the hardenability of the
material and alloying content.
• Heat resistance is the ability of a material to resist heat due to friction.
• Vibration resistance is the ability of the machine to operate in the required range of
duty without inadmissible vibration.
• Machinability: it is the property of a material that refers to a relative case with
which a material can be bend and cut.
• Cost: cost of the machine can be the initial cost, maintenance cost, and
manufacturing cost to produce the product.
13
4.1.1 Selection of material for roller

Roller used in sugarcane extraction machines is mainly subjected to external load from the
motor. And also, during the juice extraction process, the cane passes through the rollers
directly, so during this process, the cane exerts an external force on the roller. The roller
has direct contact with the sugar cane to crush so it should have to be wear resistance and
corrosion resistance. To resist this external force and to minimize wearing rate the material
selected for this part should have high strength, stiffness or rigidity, wear-resistance, and
minimum cost. The machinability also has to be excellent because there is different
machining process done on the roller like turning, facing, drilling, boring, and knurling to
have a better ground to extract the juice.
Three materials are selected which are used for manufacturing of roller this is medium
carbon steel, alloy steel, and stainless steel. Using different material properties, we
compare the three materials and select the best one by using the weighted average method.
In the table below we put some of the material properties for the three materials.
Table 4. 1 Property of materials used for the design of roller

Material property Material
Medium carbon Alloy steel 316 Stainless
steel(45C8) (42CrMo4) steel
Ultimate tensile 660 655 500-700
strength (Mpa)
Hardness, Brinell 197 197 215
Machinability 55 65 64
Thermal 49.8 42.6 16.3
conductivity
(W/mk)
Cost (USD/ton) 538-611 550-800 1200-1700
The stiffness or rigidity of all grade steel is the same so we didn’t take this factor for
comparison of the materials.
Solution
14
Table 4. 2 Weight of properties used for the design of roller.

Properties Weightage
Ultimate tensile strength 5
Hardness 4
Machinability 3
Thermal conductivity 2
Cost 5
Part I Calculation of weightage points for medium carbon steel(45C8)
Step I Points for ultimate tensile strength
The sum of the ultimate tensile strength of three materials is given by
660+655+ 650 = 1965
Therefore, for medium carbon steel(45C4), the percent strength is given by
660
= 0.336
1965
Since weightage for strength is 5, the points for medium carbon steel(45C8) is given by
0.336*5= 1.68………………………………………………(a)
Step II Points for hardness
The sum of the hardness of three materials is given by
197+197+215=609
Therefore, medium carbon steel(45C8), the percent hardness is given by
197
= 0.323
609
Since weightage for hardness is 3, the points for medium carbon steel(45C8) is given by
0.323*4= 1.292………………………………………………(b)
Step III Points for machinability
The sum of machinability of three materials is given by
55+65+64=184
Therefore, medium carbon steel(45C8), the percent machinability is given by
55
= 0.299
184
Since weightage for hardness is 3, the points for medium carbon steel(45C8) is given by
0.299*3= 0.897……………………………………………… (c)
Step IV Points for thermal conductivity
15
The sum of thermal conductivity of three materials is given by

49.8+42.6+16.3=108.7
Therefore, medium carbon steel(45C8), the percent thermal conductivity is given by
49.8
= 0.46
108.7
Since weightage for thermal conductivity is 2, the points for medium carbon steel(45C8)
are given by
0.46*2 = 0.92…...………............................................................(d)
Step V Points for cost
The points for cost are inversely proportional because a material with lower cost or points
is a better material.
The sum of cost factor is given by
1 1 1
+ + = 0.00174 + 0.00148 + 0.00069 = 0.0039
575 675 1450
Therefore, medium carbon steel(45C8), the per cent thermal cost factor is given by
0.00174
= 0.446
0.0039
Since weightage for cost factor is 5, the points for cost factor is given by
0.446*5= 2.23………………… (e)
Step VI Total points
From (a), (b), (c), (d), and (e) the total points for medium carbon steel(45C8) given by
1.68+1.292+0.897+0.92+2.23= 7.091
Part II Tabulation of weightage points
Similarly, total points for the other two materials using the same procedure are calculated
and given in the table below.
Table 4. 3 Comparison of materials used for the design of roller

Medium carbon Low alloy steel Stainless steel
Material properties Weight steel(45C8)
% Point % Point % Point
Tensile strength 5 0.36 1.68 0.334 1.67 0.33 1.65
Hardness 4 0.323 1.292 0.323 1.292 0.353 1.412
Machinability 3 0.299 0.897 0.353 1.059 0.347 1.043
16
Thermal 2 0.46 0.92 0.39 0.78 0.149 0.299

conductivity
Cost 5 0.446 2.23 0.379 1.895 0.177 0.885
Total point 7.091 6.696 5.289
Rank 1 2 3
As we have seen in the above table medium carbon steel has a higher point than the others.
So, this material is selected as a suitable material to design and manufacture rollers.
4.1.2 Material selection for shafts
Shafts used is to transfer motion and power from one machine part to another part. In our
design, the shafts are used to transmit power and motion from the motor to the roller
through pulley, v-belts, and gears. The gears and pulleys are mounted on the shaft they
exert an external force on shafts. These shafts are subjected to shear stress, bending stress,
and torsional stress. Due to this factor material selected for the shafts should have to be
rigid, high strength, toughness, and wear-resistant. Steel are stiff materials and all steels
have the same rigidity. For our design, we have selected two materials which are high
carbon steel and alloy steel which are suitable for the manufacturing of transmission shafts.
The material properties of selected materials are listed in the table below.
Table 4. 4 Properties of materials used for the design of the shaft

High Alloy steel
carbon (35Ni5Cr2)
steel(50C4)
Ultimate tensile 690 765
strength (Mpa)
Hardness, Brinell 197 225
Machinability 55 65
Thermal 49.8 42.6
conductivity (W/mk)
Cost (USD/ton) 500-650 1700
17
Now we calculate the point for each material by using a weighted average method by
following the same procedures used above. The result of each material is tabulated in the
below table.
Table 4. 5 Comparison of materials used for the design of the shaft

Material properties Weight High carbon steel(50C4) Alloy steel
% Point % Point
Tensile strength 5 0.474 2.37 0.526 2.629
Hardness 4 0.467 1.867 0.533 2.133
Machinability 3 0.458 1.375 0.542 1.625
Thermal conductivity 2 0.539 1.0779 0.461 0.922
Cost 5 0.7473 3.73 0.2527 1.2634
Total point 10.4199 8.5724
Rank 1 2
Using the five criteria, the materials for the shaft are compared. The above tables show the
result of each material and high carbon steel get a higher score. So high carbon steel is
selected as a suitable material for the design and manufacture of the shaft.
4.1.3. Material selection for the cover
Covers are used mainly as a protection for the safe operation of the machine and give
aesthetics to the machine. The material selected for this part should have to be ductile which
is measured in terms of the percentage of elongation. This is since the sheet has to be folded
easily, welded, and strong enough to withstand this machining process. We have selected
two ductile materials and have a good machinability rate which is low carbon steel and
alloy steel. Their material properties are listed in the below table.
Table 4. 6 Properties of material used for the design of the cover

Materials
Material properties Low carbon steel Alloy steel (low alloy
(mild steel 7C4) steel) A572
Ultimate tensile strength 420 450
(Mpa)
18
Elongation (in 50mm) 15 18

Machineability (100%) 65 66
Thermal 45 42.6
conductivity(W/mk)
Cost (US/per ton) 550-620 590-600
Using the same procedure, total points for each material are calculated and given in Table
4.7
Table 4. 7 Comparison of materials used for the design of the cover
Material properties Weight Low carbon steel Low alloy steel
(7C4) (A572)
% Point % Point
Ultimate Tensile strength 5 0.48 2.41 0.517 2.586
Elongation 5 0.455 2.27 0.545 2.727
Machinability 4 0.49 1.98 0.5038 2.015
Thermal conductivity 2 0.514 1.027 0.486 0.972
Cost 5 0.5029 2.514 0.442 2.21
Total points 10.201 10.511
Rank 2 1
From the table low alloy steel get a higher point than low carbon steel. So, we use low alloy
steel as a material for the design and manufacturing of the cover.
4.1.4. Material selection for bolt and frame
The same material is selected for the frame and bolt. This is because the bolt is tightened
on the frame so the frame acts like a nut. So, for better tightening and gripping of the
material, we will select the same materials. Three materials are selected those are high
carbon steel, free cutting steel, and alloy steel. Their material properties are listed in the
below table.
Table 4. 8 Properties of material used for the design of the frame

19
High carbon Free cutting Alloy steels

steel(60C4) steels 40Cr4Mo2
40C15S12
Ultimate tensile 750 640 700–850
strength (Mpa)
Hardness, Brinell 255 197 201–248
Machinability 55 65 64
Cost (USD/ton) 460-485 600-900 600-900
Using the same procedure, total points for each material are calculated and given in Table
4.9.
Table 4. 9 Comparison of materials used for the design of the frame and bolt
High carbon Free cutting Alloy steel
Material properties Weight steel (7C4) steel
% Point % Point % Point
Ultimate Tensile 5 0.346 1.732 0.296 1.478 0.358 1.789
strength
Hardness 4 0.377 1.51 0.291 1.164 0.332 1.329
Machinability 3 0.29 0.897 0.353 1.0598 0.348 1.0434
Cost 5 0.441 2.207 0.2782 1.391 0.278 1.391
Total points 6.346 5.0928 5.5524
Rank 1 3 2
The point for each material is calculated using different criteria and tabulated in the above
table. From the three materials high carbon steel gets a higher point. So high carbon steel
is selected as a suitable material for the design and manufacturing of bolt and frame.
4.1.5. Material selection for key
Keys are made of plain carbon steels like 45C8 or 50C8 to withstand shear and compressive
stresses resulting from the transmission of torque. According to Indian standards, steel of
tensile strength not less than 600 N/mm2 shall be used as the material for the key. There
are different types of a key but for our design, we compare and contrast two key types
namely saddle key and sunk key.
20
A saddle key is a key that fits in the keyway of the hub only. In this case, there is no keyway
on the shaft. Saddle keys are suitable for light-duty or low power transmission. The saddle
key requires a keyway only on the hub. Therefore, the cost of the saddle key joint is less
than that of a sunk key joint. This is the main advantage of the saddle key. The disadvantage
of the saddle key is its low power transmitting capacity. The saddle key is liable to slip
around the shaft when subjected to heavy torque. Therefore, it cannot be used in medium
and heavy-duty applications.
A sunk key is a key in which half the thickness of the key fits into the keyway on the shaft
and the remaining half in the keyway on the hub. Therefore, the sunk key is suitable for
heavy-duty application, since there is no possibility of the key slipping around the shaft. It
is a positive drive. This is the main advantage of the sunk key over the saddle key.
However, it is necessary to cut keyways both on the shaft and the hub. Therefore, the cost
of the sunk key joint is more than that of the saddle key joint.
Now we will do a comparison table for comparing the two keys.
Table 4. 10 Weightage of points for comparison of keys

Grades 1 2 3 4 5
Values Poor Bad Good Very good excellent
Table 4. 11 Comparison of saddle key and sunk key

Criteria Weight Saddle key Sunk key
% Score Unit Score Unit
Strength 20 3 0.6 5 1
Power transmission 25 3 0.75 5 1.25
capacity
Resistance to slip 15 3 0.45 5 0.75
Stability 15 3 0.45 5 0.75
Cost 25 5 1.25 3 0.75
Total 100 3.5 4.5
Rank 2 1
21
The above decision matrix table shows a comparison of key using five criteria. The result
show sunk key has a higher total point. So, we select sunk key which is made of plain
carbon steel as an appropriate material for our design.
4.1.6 Selection for power transmission
Mechanical power transmission system retrieves mechanical power from prime movers
and subsequently delivers the same to the machine unit. It can also change the direction of
rotation and alter the rotational speed to better match the requirement. The transmission
system includes four drives (gear drive, belt drive, chain drive, and rope drive). Each drive
has certain advantages over others and is suitable for specific applications.
These four mechanical drives can be classified in several ways. Based on the means of
power transmission, such drives can be classified as friction drive and engagement drive.
In friction drives, power is transmitted employing friction force between two mating parts,
as in the case of belt drive and rope drive. In engagement drive, power is transmitted
through successive engagement and disengagement, as in the case of chain drive and gear
drive.
Table 4. 12 Selection of power transmission method
No Criteria Types of mechanical drive

Flat belt V- belt drive Chain drive Gear
drive drive
1 Velocity Not Not constant Not constant Constant

ratio constant
2 Power Low Good High High

transmission
3 Slip Slippage Comparatively Not positive No-slip,

small slip drive and slip positive
occurs drive
4 Center Long Comparatively Medium Short
distance short
5 Efficiency Very Good Excellent Excellent
good
6 Absorb Excellent Excellent Not good Not good
shock and
damp
vibration
22
7 Noise More Less noise Higher noise Have a

noise noise
8 Compact Not Suitable Not suitable Suitable
layout suitable
9 Ease of Relatively Relatively Complex Complex
maintenance simple simple
10 Cost Cheapest Relatively Comparatively Costlier
cheap costly
From the above table, we have listed different criteria for each mechanical drive. For our
design, we have given more attention to power transmission, efficiency, compact layout,
and cost. By comparing these criteria for our design, we select a V-Belt drive.
4.1.7 Selection of gear type for gearbox
Generally, there are four types of gears those are spur gear, helical gear, bevel gear, and
worm gear. The first two gears are used for parallel shafts and the second two shafts are
used for non-parallel and perpendicular shafts. For our machine design, we use a parallel
shaft because the rollers are assembled parallel to each other. So, we compare and contrast
spur and helical gears for our design. The properties of the gears are listed the below table
which helps us to decide the suitable gear type for design.
Table 4. 13 Comparison of the spur gear and helical gear
Properties Types of gear

Spur gear Helical gear
The layout of the Parallel and coplanar Parallel shaft and non-parallel shafts
shaft shaft
Velocity ratio 1:1 to 1:3 1:1 to 1:5
Speed Low and moderate speed Low to high-speed application
Power transmitted Low power transmission High power transmission
Load tolerance Holding Less load Holding More load
Durability Shorter life Longer life
Noise Louder Quieter
Efficiency More efficient Less efficient
Ease of manufacture Easy Comparatively complex
Cost Less cost 1.50-4.00 More cost 3-50
Table 4. 14 Weightage of points used to select gear
Grades 1 2 3 4 5
23
Table 4. 15 Selection of gear for sugar cane machine

No Criteria Weightage Types of gear
(100%) Spur gear Helical gear
Unit Score Unit Score
1 Speed 20 3 0.6 5 1
reduction
2 Efficiency 25 5 1.25 3 0.75
3 Noise 10 2 0.2 4 0.4
4 Durability 10 3 0.3 5 0.5
5 Ease of 10 5 0.5 2 0.2
manufacture
6 Cost 25 5 1.25 2 0.5
7 Total 100 4.1 3.35
8 Rank 1 2
From the above decision matrix table, we have selected spur gear for our gearbox
4.1.8 Selection of bearing type
Bearings are generally two types sliding contact bearing and rolling contact bearing.
Sliding contact bearings are used in the following applications: crankshaft bearings in
petrol and diesel engines, centrifugal pumps, large size electric motors, steam and gas
turbines, concrete mixers, and rope conveyors.
Rolling contact bearings are used in the following applications machine tool spindles,
automobile front, and rear axles, gearboxes, small size electric motors, rope sheaves, crane
hooks, and hoisting.
For our design, we have selected a rolling contact bearing because we use a small size
electrical motor. There are also different types of roller contact bearing deep groove ball
bearing, cylindrical roller bearing, self-aligning bearings, taper roller bearing, thrust ball
bearing.
Table 4. 16 Weightage of points used to select the bearing

Grades 1 2 3 4 5
24
Table 4. 17 Comparison of different types of bearing

Types of bearing
Deep groove Cylindrical Angular Tapper roller Thrust roller
Criteria Weight ball bearing roller bearing contact bearing bearing
(100%) bearing
Unit Score Unit Score Unit Score Unit Score Unit Score
Radial load
carrying
capacity 15 4 0.6 5 0.75 5 0.75 5 0.75 1 0.15
The axial
load carrying
capacity 15 4 0.6 1 0.15 5 0.75 5 0.75 5 0.75
Rigidity 10 2 0.2 3 0.3 2 0.2 5 0.5 3 0.3
Ease of 10 4 0.4 4 0.4 4 0.4 5 0.5 4 0.4
assembly
Noise 25 5 1.25 2 0.5 5 1.25 2 0.5 2 0.5
Cost 20 5 1 4 0.8 1 0.2 1 0.2 3 0.6
Total 100 4.05 2.9 3.55 3.2 2.7
Rank 1 4 2 3 5
For our design, we select a deep groove ball bearing.
4.2 Design calculation

For the design of the sugarcane juice extractor, we have taken some assumptions based on
the existing machine and some other parameters.
Design considerations;
The following factors were considered during the design of the sugarcane juice extractor:
I. The machine is composed of 3 rollers.
II. Roller diameter of 100 mm for each for effective compression of cane
III. The length of the roller is selected to be 150mm, based on the number of canes it
can accommodate at a time.
4.2.1 Design of roller
4.2.1.1 Determination of cane size
We have measured 4 different sizes of cane to obtain the maximum and minimum size of
cane that can be crushed by the machine. From the experiment we have made so far, by
25
measuring 4 cane we get the mass and diameter. Measured values are listed in the table
below: -
Table 4. 18 Measured value of different size sugar cane

No Type Mass(kg) Diameter(mm)
1 Small 0.6 32.5
2 Medium 1 0.9 47.75
3 Medium 2 1.3 52.5
4 Large 1.5 59.8
So, the max size of the cane is 60mm and the minimum size is 33mm.
4.2.1.2. Size of roller to accommodate the varying sizes of sugarcane
The clearance that can accommodate the maximum and minimum size of sugarcane stalks
that can be fed into the extractor is determined using equation (1)
𝑙
𝑅+
2
𝑥1 = 2 (𝐶𝑂𝑆𝜃 − 𝑅)……………………………... (1)
Where;
X1 = Maximum size of sugarcane that can be fed into the machine
R = Radius of the roller, mm
L = Clearance between the top and feed roller, mm
2𝜃 = Nip angel
The nip angle is a function of the coefficient of friction, µ, between the roller surface and
the sugarcane surface, and the relationship between the nip angle and the coefficient of
friction is such that;
𝜃=tan−1 𝜇
where;
µ = coefficient of friction between the roller surface (medium carbon steel) and the
sugarcane.
µ = 0.35
𝜃=tan−1 0.35
θ = 19.29≈ 20°
From equation 1 the formula of clearance is derived below:
𝑋
L = 2( 21 + 𝑅) cos 𝜃 − 2𝑅
60
L = 2( 2 + 50) cos 19.29 − 2(50)
Lmax = 51.02mm ≈ 50𝑚𝑚
33
Lmin = 2( 2 + 50) cos 19.29 − 2(50)
Lmin = 25.5mm ≈ 26𝑚𝑚
For the design purpose, we select the minimum gap between the two rollers which is 26mm.
26
4.2.1.2. Thickness of roller
A hollow cylindrical shaft is used to build the roller, this hollow shaft’s thickness must be
calculated to check for its ability to withstand the compressive strength of the sugar cane
by equation (2).
𝑝×𝑑
t= ……............................................................... (2)
2𝜎𝑡
where;
t = thickness of the roller
σt = tensile strength of the roller 660Mpa
p = roller pressure, 20Mpa
d = diameter of the roller,
20×100 2000
t= = = 1.5 ≈ 5𝑚𝑚
2×660 1320
It is the minimum thickness of the roller to withstand the compression strength.
4.2.1.3. Weight of crushing rollers
The weight of the crushing roller is estimated from equation (3).

W = 𝜌𝑣𝑔………....……………………………………… (3)
Where;
W = weight of crushing roller, N
𝜌 = The density of the crushing roller material 7850 kg/m3
v = Material volume of the roller, m3
g = Acceleration due to gravity, 9.8 m/s2
The volume of the roller is calculated using the following formula,
𝜋𝐷 2 𝜋𝑑2 𝜋𝑑2
𝑉=( − )𝑙 + 2( ) 𝑡……… (4)
4 4 4
Where D=Outer diameter of the roller; di = inner diameter of the roller; l= length of the
roller t= thickness of roller.
From Eqn 3 and 4 we can determine the weight of the roller,
𝜋𝐷2 𝜋𝑑 2 𝜋𝑑 2
𝑤 = 𝜌 × [( − )𝑙 + 2( ) 𝑡] × 𝑔
4 4 4
𝜋0.12 𝜋0.0952 𝜋0.0952

𝑤 = 7850 × [( − ) 0.15 + 2 ( ) 0.005] × 9.8
4 4 4
𝑤 = 11.56𝑁
4.2.1.4 Crushing force of rollers
The crushing force on the roller is expressed as given in equation 5.

𝐹𝑐 = 𝑅𝑓 × 𝐹𝑠 ………………. (5)
Where;
Rf = Rapture force of sugarcane = 50N
Fs= Factor of safety = 2
27
𝐹𝑐 = 50𝑁 × 2
𝐹𝑐 = 100𝑁
4.2.1.5 Crushing torque of roller
The crushing torque on the roller is expressed as given in equation 6.

𝑇 = 𝐹𝑐 × 𝑟………………………. (6)
Where;
T= torque on the shaft
Fc=crushing force of sugar cane
r= radius of the roller
𝑇 = 100 × 0.05
𝑇 = 5𝑁𝑚
4.2.1.6 Rotating speed of the roller
The choice of roll speed affects the production rate. Low speed is required for large
diameter rolls, while for smaller rolls high speed is required. Wills and Napier Munn, [17]
indicated that the peripheral speed of rolls ranges from 1m/s for small rolls to 15m/s for
the largest rolls.
For our design, we select a velocity of 1 m/s.
By converting velocity to rpm and angular velocity the corresponding values can be found.
• Speed of crushing roller
60
𝑁(𝑟𝑝𝑚) = 2𝜋𝑟 𝑣 ……………………… (7)
60
= 2𝜋0.05 1 𝑚⁄𝑠
= 191𝑟𝑝𝑚 ≈ 200𝑟𝑝𝑚
• Angular velocity crushing roller determine from equation 7,
2𝜋𝑁 2𝜋200
𝜔 = 60 = 60 = 21𝑟𝑎𝑑/𝑠
4.2.2 Selection of motor
4.2.2.1 Design of motor power
A velocity ratio of 5 is chosen between the motor and the crushing roller. That will be
achieved through the combination of belt drive and gear train.
𝜔𝑚 = 𝜔𝑟 × 5 = 21 × 5 = 105𝑟𝑎𝑑/𝑠
The power required is calculated using equation 8
P = T × 𝜔𝑚 ………………… (8)
𝑟𝑎𝑑
P = 5 Nm × 105 𝑠
P = 525 w = 0.525kw
0.525𝐾𝑤 × 1000
Hp = = 0.7 Hp ≈ 2𝐻𝑝
746
2Hp motor of 1000 rpm is selected.
28
4.2.2.2 Selection of motor type

Specification of the motor
Power = 2HP
Speed= 1000rpm
Torque= 5Nm
Suitable motor type for our machine is selected based on the most important criteria used
for motor selection minimum and maximum achievable speed, torque at the load shaft, and
power. For the design of the sugar cane juice extractor machine selected motor type is a
DC motor that can work within the range of speed of 350-6000 rpm and medium HP with
an efficiency of 60 -70 % from quick reference guide motors available in appendix 1.
Table 4. 19 Comparison of dc motors

Criteria Types of DC motor
Permanent Series Shunt Compound
magnet
Cost Cheaper High High operation
installation cost and
maintenance
cost
Size Small Medium Large Medium
Life Good Good Good Less than series
The load they limited to some Cannot run at For constant Can run at no
can drive amount of load no-load load load
condition
Speed good speed Poor good Good
regulation regulation
Starting torque excellent High Medium High
starting torque
Based on the criteria listed above permanent magnet DC motor is selected over the three
types of DC motors (i.e., series dc motor, shunt dc motor, compound dc motor).
4.2.3 Design of pulley and V-belt
4.2.3.1 selection of belt
V belts are made in five types i.e. A, B, C, D and E based on the power range they can
work with. Depending on the motor power for our machine (i.e., 1.5KW) we select A type
belt from the 5 types of belts shown in appendix 2.
Standard dimensions of A type v belt are: -
29
Top width(b)= 13mm

Thickness(tb)= 8mm
No. of sheave grooves (n)= 6
Groove angle in degrees (2β) =340
4.2.3.2 Design of pulley diameter
Design of driving pulley

The diameter of the power shaft pulley is determined by applying equation 9,
1
𝐷1 = 58(𝑇)3 ……………… (9)
1
= 58(5)3 = 99.2𝑚𝑚 ≈ 100𝑚𝑚
Design of driven pulley
𝐷2 𝑁
= 𝑁1 …………………… (10)
𝐷1 2
Where D1 =diameter of the driving pulley

D 2=diameter of the driven pulley
N1=speed of the driving pulley
N2= speed of driven pulley
The speed of the motor is required to be reduced 5 times to its original value, but in the belt
drive only half of the speed is reduced (i.e., 1:2).
𝑁 1000
 𝑁1 = 2, 𝑁2 = = 500𝑟𝑝𝑚
2 2
From equation 10 we will determine the diameter of the load shaft pulley,
𝑁1
𝐷2 = 𝐷1 ×
𝑁2
𝐷2 = 100 × 2 = 200mm
Ideally, the power shaft pulley should be 3 inches (76.2mm) and more, and the load shaft
pulley less than 12 inches (304.8mm). Since the designed parameter is within the range the
diameter of the power shaft pulley and load shaft pulley diameter is acceptable.
4.2.3.3 Design of center distance between the pullies

For a V-belt, the center distance can be calculated by: -
C = 0.55 (D2 + D1) + tb…………………… (11)
Let’s select a V type belt with tb (thickness) 8mm from machine design by Rs kurmi.
30
𝐶 = 0.55(100 + 200) + 8
𝐶 = 173 ≈ 175𝑚𝑚
4.2.3.4 Design of angle of contact/lap
The angle of contact for the driving pulley is calculated using equation 12,
𝜋
𝜃 = ( 180 − 2𝛼) ………………….. (12)
180
𝐷2 − 𝐷1
𝛼 = sin−1 ( ) …………………… (13)
2𝐶
Where 𝜃 = angle of lap for driving pulley

C = center distance
D1 = diameter of the driving pulley
D2 = diameter of the driven pulley
200 − 100
𝛼 = sin−1 ( )
2(175)
α = 16.6º
𝜋
𝜃 = ( 180 − 2 × 16.6) 180
𝜃 = 2.6 rad
4.2.3.5 Design of belt length
For an open V-belt drive, the length of the belt is given by,
(𝑟2 −𝑟1 )2
𝐿 = 𝜋(𝑟2 + 𝑟1 ) + 2𝐶 + …………………. (14)
𝐶
(100 − 50)2
𝐿 = 𝜋(100 + 50) + 2(175) +
175
𝐿 = 471.24 + 350 + 14.3 𝐿 = 835.5 mm
𝐿 = 0.836 ≈ 1𝑚
4.2.3.6 Design of belt tension
For (a) type belt
b = 13 mm
t = 8mm
T1 = T – Tc
T=𝜎 ×𝑎
= 2.5Mpa × (13 × 8)
= 260N
TC = mV2
31
m = (a × L × 𝜌)
= 0.013 × 0.008 × 1 × 1000
= 0.104 kg
𝑉 = 𝜔𝑟2
= 105 × 0.1
= 10.5 m/s
TC = 0.104× (10.5)2
TC = 11.47 ≈ 12𝑁
T1 = T – Tc
T1 = 260 – 12
T1 = 248 N
To find tension in the slack side
𝑇 34°
2.3 log 𝑇1 = 𝜇. 𝜃. csc …………………………… (15)
2 2
𝑇 34°
2.3log 𝑇1 = 0.25 × 2.5 𝑟𝑎𝑑 csc
2 2
𝑇 0.25 ×2.5 ×3.42
log 𝑇1 =
2 2.3
𝑇
log 𝑇1 = 0.92935
2
𝑇1
= 8.499 ≈ 8.5
𝑇2
1 𝑇 248
T2 = 8.5 = 8.5
𝑇2 = 29.2N
4.2.4 Design of shaft diameter
4.2.4.1 Design of shaft based on strength
Material selected high carbon steel(50C4)
Tensile strength, syt = 660N/mm2
Shear stress, sys = 0.5syt = 330N/mm2
Factor of saftey, f.s = 2
Allowable shear stress, s = sys/f.s = 165N/mm2
The diameter of the shaft is calculated using the following formula:
16
d3 = 𝜋 𝜏 √(𝐾𝑏 × 𝑀𝑏 )2 + (𝐾𝑡 × 𝑀𝑡 )2 …………. (16)
𝑠
32
Where;
Mb= bending moment, N mm
Mt= tortional moment, N mm
Kb= combine shock and fatigue factor applied to bending moment = 1.5
Kt= combine shock and fatigue factor applied to bending moment = 1.0
s= allowable shear stress for shaft with key way
D= shaft diameter, mm
Mt = 5 Nm
Mb = weight of pulley + (T1 + T2)
= 26 N + (248+29.2)
= 303.2 Nm
16
d3 = 𝜋 √(1.5 × 303.2)2 + (1 × 5 )2 = 1.403×10-5
× 165 ×106
d = 0.024m or 24mm
Let’s take the diameter of the shaft 25 mm.
4.2.4.2 Design of shaft based on rigidity

584𝑀𝑡 𝐿
𝑑4 = ……………………………. (17)
𝐺𝜃
Where, L =length of shaft (500mm)

G=modulus of rigidity (80 GPa)
𝜃= angular deflection (0.5)
d= diameter of shaft
584𝑀𝑡 𝐿
𝑑4 =
𝐺𝜃
584 × 5 × 0.5
𝑑4 =
80 × 109 × 0.5
𝑑 = 0.014𝑚
𝑑 = 14𝑚𝑚
For the design purpose, we will select the maximum amount of shaft diameter which is 25
mm.
∴ Equivalent twisting moment on the shaft from eqn 3.27,
Te = ( (Mt)2+ (Mb)2)1/2 = ( (5 )2+ (302.2)2)1/2
= 302.241×10 3 N-MM
33
Let us now check the maximum shear stress induced.

We know that the actual shear stress,
16 𝑇 16 × 302241
τ = 𝜋( d)3 = = 98.52 N/mm2
𝜋( 25)3
and direct compressive stress on the shaft due to the axial force,
𝑊𝐴 572.8
σc = 𝜋 =𝜋 = 1.166 N/mm2
( d)2 ( 25)2
4 4
Maximum shear stress,

τmax = ½ ((σc2 + 4τ2 )1/2 ) = ½ ((98.522 + 4(1.166)2 )1/2 ) = 49.27 N/mm2
Since the maximum shear stress induced is less than allowable shear stress (165 Mpa),
therefore the design of shaft is satisfactory according to maximum shear stress theory.
4.2.5 Design of key
Material selected plain carbon steel (50C4)
Tensile strength, syt = 660 N/mm2
Factor of safety, f.s = 2
Let b = width of the key (mm)
h = height or thickness of the key(mm)
l = length of the key(mm)
d = diameter of the shaft(mm)
T= torque transmitted by the shaft is 1313.03 x103 N.mm
For key material, the yield strength in compression can be assumed to be equal to the
yield strength in tension.
Syc =Syt = 660 N/mm2
𝑠𝑦𝑐
Finding permissible stress, 𝜎𝑐 = …………… (18)
𝑓.𝑠
660
= = 330 𝑁⁄𝑚𝑚2
2
𝑠𝑠𝑦
According to the maximum shear stress theory of failure, 𝜏 = ………..(19)
𝑓.𝑠
Ssy = 0.5 Syt = 0.5 (660) = 330 N/mm2

330
From eqn 19, 𝜏 = = 165 𝑁⁄𝑚𝑚2
2
The values of b and h are taken from a table which is attached in the appendix (), for shaft
diameter 22 to 30 mm.
34
 b×h = 8×7 mm and keyway depth 4 mm

The length of the key is obtained by considering the key in shearing and crushing.
A little consideration will show that due to the power transmitted by the shaft, the key
may fail due to shearing or crushing.
Length = 1.5d = 1.5×25 = 37.5 mm
Considering crushing of the key, the tangential crushing force acting at the circumference
of the shaft,
ℎ
F = Area resisting crushing × Crushing stress = l × 2 × σc ……. (20)
∴ Torque transmitted by the shaft,

𝑑
T=F× ……… (21)
2
ℎ 𝑑
T = l × 2 × σc × 2
T = 37.5 ×3.5×330×12.5 = 541,406.25 N-mm

Now let us check shear stress induced in the material,
2𝑇 2(541,406.25 )
𝜏 = 𝑑𝑏𝑙 = = 144.375 Mpa
(25)(8)(37.5)
And crushing stress-induced,

4𝑇 4(541,406.25 )
𝜎𝑐 = 𝑙𝑑ℎ = = 330 Mpa
(37.5)(25)(7)
 Maximum shear stress induced in the material is,

τmax = ½ ((σc2 + 4τ2 )1/2 ) = ½ ((3302 + 4(144.375)2 )1/2 )= 219 Mpa
Since the maximum shear stress-induced is less than permissible shear and compressive
stress (330 Mpa), therefore the design of the key is satisfactory according to maximum
shear stress theory.
4.2.6 Design of bolt
The bolt and the frame are made from the same material since the frame act like a nut. So,
the material used for the construction of the bolt is high carbon steel.
Ultimate tensile strength=750 Mpa
Factor of safety=5
35
The crushing force is the force applied on the bolt, there is a total of 18 bolts used in the
design of the sugar cane machine. Only considering bolt that has a direct relation crushing
system.
𝐹
𝑃 = 𝑛𝑢𝑚𝑏𝑒𝑟𝑐𝑜𝑓 𝑏𝑜𝑙𝑡 ……………… (21)
100𝑁
𝑃= = 5.6𝑁
18
Design of core bolt diameter can be found from the following formula,
𝑃
𝜎𝑡 = 𝜋 2 …………………………. (22)
𝑑
4 𝑐
Where, 𝜎𝑡 =maximum tensile stress in the bolt at this cross-section

P=tensile force
dc=core diameter of the bolt
𝑠𝑦𝑡
𝜎𝑡 = …………………………. (23)
𝑓.𝑠
750
𝜎𝑡 = = 150 𝑁⁄𝑚𝑚2
5
4𝑃 4×5.6
𝑑𝑐2 = 𝜋𝜎 =
𝑡 𝜋150
𝑑𝑐 =0.2mm
𝑑𝑐 = 0.8𝑑………………………… (24)
𝑑
𝑑 = 0.8𝑐 = 0.25𝑚𝑚
Fine threads offer greater strength when subjected to fluctuating loads and they have
greater resistance to unscrewing as a result of lower helix angle and they are more
dependable than threads with a coarse pitch in respect of self-unscrewing. Threads with
fine pitch are selected for the design of the bolt. Taking the standard size of a bolt from
fine trade series attached in appendix () a bolt M6 x1 is selected.
4.2.7 Design of gear
4.2.7.1 Design of gear train
The simple or compound gear train is used based on gear ratio to change the value of speed
or torque. For gear ratio, less than and equal to 10:1 a simple gear train is used unless a
compound gear train is used.
𝑁
𝑚𝑣 = 𝑁 𝑖𝑛 ………………………… (25)
𝑜𝑢𝑡
36
Where, mv= gear ratio

Nin =speed of pinion
Nout =speed of gear
𝑁 500
 From equation 25, 𝑚𝑣 = 𝑁 𝑖𝑛 = 200 = 2.5
𝑜𝑢𝑡
Since the gear ratio is less than 1:10 we use a simple gear train
4.2.7.2 Design of pinion

Assumption
I. Pressure angle of 200 is selected,
II. The module of the pinion is 2
III. For 200 pressure angles to avoid interference between full depth gear and full depth
pinion minimum number of pinion teeth should be 18. Therefor we select the
number of teeth of the pinion gear is 25.
• Pitch circle diameter of a pinion (dp)
𝑑𝑝 = 𝑚𝑜𝑑𝑢𝑙𝑒 × 𝑁………………… (26)
= 2 × 25 = 50𝑚𝑚
• Pitch radii of a pinion (rp)
𝑑𝑝
𝑟𝑝 = ………………………. (27)
2
50
𝑟𝑝 = = 25𝑚𝑚
2
• Circular pitch (pc)

𝜋𝑑
𝑝𝑐 = ……………………… (28)
𝑁
𝜋(50)
= = 6.28𝑚𝑚
25
• Base pitch (pb)

𝑝𝑏 = 𝑝𝑐 𝑐𝑜𝑠 ∅ …………………… (29)
𝑝𝑏 = 6.28𝑐𝑜𝑠 200
𝑝𝑏 = 5.9𝑚𝑚
• Diametral pitch (pd)
𝜋
𝑝𝑑 = 𝑝 …………………………… (30)
𝑐
𝜋
𝑝𝑑 =
6.28
37
𝑝𝑑 = 0.5𝑚𝑚
• The addendum(a)
1.0
𝑎= …………………………. (31)
𝑝𝑑
𝑎=2
• The dedendum (b)
1.25
𝑏= ………………………. (32)
𝑝𝑑
𝑏 = 2.5
• The whole depth (ht)
ℎ𝑡 = 𝑎 + 𝑏 ……………………. (33)
ℎ𝑡 = 2 + 2.5= 4.5
• Clearance (c)
𝑐 = 𝑏 − 𝑎 ………………………. (34)
= 2.5 − 2 = 0.5
• The outside diameter (Dop) of each gear
𝐷𝑜𝑝 = 𝑑𝑝 + 2𝑎 ……………… (35)
= 50 + 2 × 2 = 54𝑚𝑚
4.2.7.3 Design of gear
• Number of teeth of a gear,
It can be found from the gear ratio
𝜔𝑜𝑢𝑡 𝑁
= 𝑁 𝑖𝑛 ………………… (36)
𝜔𝑖𝑛 𝑜𝑢𝑡
𝜔
𝑁𝑜𝑢𝑡 = 𝑁𝑖𝑛 (𝜔 𝑖𝑛 )
𝑜𝑢𝑡
680
= 25 (272)= 63
• The diametrical pitch of gear,

The diametrical pitch of the two meshing gear should be the same.
𝑝𝑑 𝑝𝑖𝑛𝑖𝑜𝑛 = 𝑝𝑑 𝑔𝑒𝑎𝑟 ……………. (37)
𝑝𝑑 = 0.5𝑚𝑚
• Pitch circle diameter of gear(dg),
𝑁
𝑝𝑑 = ……………………. (38)
𝑑
38
𝑁 63
𝑑= = = 126𝑚𝑚
𝑝𝑑 0.5
• Pitch radii of gear (rg)
𝑑𝑔
𝑟𝑔 = ………………………. (39)
2
126
𝑟𝑔 = = 63𝑚𝑚
2
• The outside diameter of gear (Dog)

𝐷𝑜𝑔 = 𝑑𝑔 + 2𝑎 ……………… (40)
= 126 + 2 × 2 = 130𝑚𝑚
• Nominal center distance(C)
It is the sum of pitch radii of the two gears,
C = 𝑟𝑝 + 𝑟𝑔 ………………… (41)
C = 25 + 63 = 88𝑚𝑚
• Mounting distance
It is the sum of the pitch diameter of the two gear,
𝑑𝑝 +𝑑𝑔
Mounting distance = …………… (42)
2
50+126
= = 88𝑚𝑚
2
4.2.7.4 Stress analysis on the spur gear

First lets us find the torque on the spur gear
𝑃×60
T = 2𝜋×𝑁 ………………………………….. (43)
𝑃
Where p is the power of the motor, 2Hp = 1.5 kW

NP is the speed of the pinion, 500 r.p.m
Form equation 43,
1500×60
T= = 28.64 Nm
2𝜋×500
We know that tangential force on the tooth,

2 ×𝑇𝑔𝑒𝑎𝑟
WA = Axial force on the tooth, …………. (44)
𝐷𝑃
2 ×28.64
= = 572.8 N
0.1
Normal load on the tooth on the tooth,

𝑊
WN = cos𝑇𝜑…………………………………………. (45)
39
572.8
WN = cos 20º = 609.56 N
and radial or separating load on the tooth,

WR = Radial or separating force on the tooth
= WN . sin φ……………………………………. (46)
= 609.56 × sin 20° = 208.48 N
4.2.8 Bearing selection
The bearing selected for our design is a deep groove ball bearing. Now we select the
appropriate size of bearing.
From the gear
Tangential load, WT = 572.8 N
Normal load, WN = 609.56 N
Radial load, WR = 208.48 N
Shaft diameter, 25 mm
Life of bearing in an hour, L10h =16,000 hr
Speed, 200 rpm
Fr= 208.48 N, Fa = 572.8 N
X= 0.56, y= 1.5
P = X Fr + Y Fa……………………………………….(47)
P = 0.56(208.48) + 1.5(572.8)
P = 975.95 N
L10h = 60N L10h / 106
L10h = 60×200×16,000 / 106 = 192 million rev
C = P(L10h)1/3…………………………………………. (48)
C = 975.95(192)1/3
C= 5630.25 ≈ 7610
CO = 4000
From appendix 3 Bearing No. (16005) with an outer diameter of 47mm and width of 8
mm is selected
 d = 25mm, D= 47 mm, B= 8mm.
4.2.9 Design of frame
Material selected high carbon steel
40
Tensile strength, syt = 330N/mm2

Factor of safety, f.s = 2
Allowable shear stress, 𝜏 = 165 𝑁⁄𝑚𝑚2
Since the bearing is fitted in the housing the thickness of the housing is equal to the
bearing face width is 8 mm from the table.
The width of the roller is equal to the width of the bearing, and clearance.
W=8+2=10mm
The depth of the frame is equal to the summation of the center distance between the gear,
radius of two gears, and clearance.
D= 150+ 65×2+30
D= 310mm
The height of the frame is the center distance between the three gears, the radius of the
two gear, and some clearance
H = 102+65×2+115 = 347 mm
Let us now check the induced shearing stress in the frame by using shear stress theory.
We know that the maximum driving torque transmitted,71625Nmm
𝜋
Tmax = d2 x τ x t ……………………………. (49)
2
𝜋
71625 N-mm= 2 x 472 x τ x 10
τ = 2.064Mpa
Since the induced shear stress in the frame is less than 165 MPa, therefore the design of
the frame is safe.
4.2.10 Stress analysis of roller
4.2.10.1 Analytical calculation for stresses on the top roller
The top roller is most highly stressed since it consumes about half of the mill torque. The
forces on the top roller are because of power transmission, crushing load. The loads on the
roller are divided into a horizontal and vertical component of loading.
Power(p)= 1.5 kw
Roller Speed (n)= 200 rpm
Roller diameter = 100mm
Roller shaft diameter =25 mm
Pitch circle dia. of crown pinion= 50mm
41
P×9.55
Drive torque = 𝑠𝑝𝑒𝑒𝑑(𝑟𝑝𝑚) ……………………………. (50)
1500×9.55
= = 71.625Nm = 71625Nmm
200
Out of the total torque, 50% of the torque is taken by top roller,
So, Torque on the top roller = 35,812.5 N-mm
Tangential component (Horizontal) of force due to torque
𝑡𝑜𝑟𝑞𝑢𝑒
WT= 𝑃.𝐶.𝐷/2 ………………………………... (51)
35812.5
= =1432.5 N
50/2
Radial component (Vertical) of force due to torque

𝑊
WR=WNsin 𝜑 = cos𝑇𝜑 sinφ
1423.5
WR = sin 20 = 521N
cos 20
A load of crushing from the discharge roller is acting at an angle of 20º from the right
side is100N.
The vertical component of load= 34.20 N
The horizontal component of load (left)= 93.96 N
A load of crushing from the feed roller is acting at an angle of 22º from the left side is
50N.
The vertical component of load=38.3 N
The horizontal component of load (right) =46.3 N
The weight of the top roller is 11.6 N which is acting downwards.
The total vertical load acting on the roller = 34.20+38.3- 11.6 = 61N
The total horizontal load acting on the roller =93.96 – 46.3 = 48N
A load of crushing is acting on the surface of the roller so, it will be shown as a uniformly
distributed load on the loading diagram
The intensity of U.D.L. in vertical loading diagram
𝑇𝑜𝑡𝑎𝑙 𝑣𝑒𝑟𝑡𝑖𝑐𝑎𝑙 𝑑𝑢𝑒 𝑡𝑜 𝑐𝑟𝑢𝑠ℎ𝑖𝑛𝑔 61
(Wv)= =230 = 0.2652 N/mm
𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑠ℎ𝑒𝑙𝑙 𝑜𝑓 𝑟𝑜𝑙𝑙𝑒𝑟
The intensity of U.D.L. in horizontal loading diagram

𝑇𝑜𝑡𝑎𝑙 ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 𝑑𝑢𝑒 𝑡𝑜 𝑐𝑟𝑢𝑠ℎ𝑖𝑛𝑔 48
(Wh)= =230 = 0.2087 N/mm
𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑠ℎ𝑒𝑙𝑙 𝑜𝑓 𝑟𝑜𝑙𝑙𝑒𝑟
42
Vertical load diagram

WR
A B C D E F
RF
RB L2 WV L2
L3
L1 L
Here,
L= 230mm
L1=165mm
L2= 40mm
L3= 150mm
WR = Vertical component of force due to torque=521N
W= Intensity of U.D. L= 0.2652N/mm 0.2652 × 150 =39.78 N
Ra and Rg are reaction forces from bearing.
+ ∑ 𝐹 = 0 , RB+RF+WV - WR=0
RB+RF= WR-WV = 521-39.78 = 481.22N
+ ∑ 𝑀𝐹 = 0, WR× (L1+L2)- RB(L)-WV(L3/2+L2) =0
RB = 521(395)-39.78(115)/230
RB = 874.87N
 RF = 481.22 -874.87 = -393.65 N
+ ∑ 𝑀𝐷 , WR (280)- RB (115) +RF (115) =0
521(280)- 847.87(115)-393.65(115) =0
MD = 3105.2Nm
43
Horizontal load diagram
WT
RF
RB L2 Wh L2
L3
L1 L
WT = Horizontal component of force due to torque=1432.5N
W= Intensity of U.D. L= 0.2087N/mm= 0.2087 × 150 =31.305N
Ra and Rg are reaction forces from bearing.
+ ∑ 𝐹 = 0 , RB+RF-Wh – WT =0
RB+RF= WT + Wh = 5 = 1432.5 +31.305 = 1463.805N
+ ∑ 𝑀𝐹 = 0, WT (395)- RB (230) +Wh (115) =0
RB = (1432.5(395) +31.305(115))/230
RB = 2475.82N
 RF = 1463.805 -2475.8 = -1012.01N
+ ∑ 𝑀𝐷 , WT (280)- RB (115) +RF (115) =0
1432.5(280)- 2475.82(115)-1012.01(115) =0
MD = -0.45 Nm
Resultant of vertical and horizontal
Resultant reaction at ‘b’= 2625.83N
Resultant reaction at ‘f’ = 1085.87N
44
Resultant bending moment at ‘D’ = 3105.2×104Nmm
Torque on the top roller = 35,812.5 N-mm
Maximum shear stress
According to shear stress theory
16
𝜏𝑚𝑎𝑥 = √𝑀2 + 𝑇 2
𝜋𝑑3
16
𝜏𝑚𝑎𝑥 = √3105.2 × 104 2 + 35812.52 =158.2 MPA
𝜋1003
The material used for the roller is medium carbon steel Syt=330 N/mm2
Therefore Ssy=0.5×330=165N/mm2
Therefore, the shaft is safe according to maximum shear stress theory.
4.2.10.2 Analytical calculation for stresses on the discharging roller
The geometry and material of the discharge roller are the same as the top roller. The loads
acting on the roller are due to the crushing of sugarcane between the top and discharge
roller and the load due to torque. Out of the total torque, 35 % torque is taken by discharge
roller. The same procedure of horizontal and vertical loading diagram is used for finding
the value of maximum shear stress.
Out of the total torque, 35% of the torque is taken by discharge roller,
So, Torque on the discharge roller = 25.0687N-m
Tangential component,
𝑡𝑜𝑟𝑞𝑢𝑒 25068.7
WT= 𝑃.𝐶.𝐷/2 = =1002.78N
50/2

𝑊𝑇
WR=WNsin 𝜑 = sinφ
cos 𝜑
1002.78
WR = sin 20 =364.97N
cos 20
The resultant reaction at ‘b’= 1840.73N

The resultant reaction at ‘f’= 758.025
The resultant bending moment at ‘D’ = 2593.4×104 Nmm
Max. Shear stress = 75 Mpa
Therefore, the shaft is safe according to shear stress theory.
45
4.2.10.3 Analytical calculation for stresses on the Feed roller: -

The same Geometry and material of the top roller are used for the feed roller. The loads
acting on the roller are due to the crushing of sugarcane between the top and Feed roller
and the load due to torque. Out of the total torque, 15 % torque is taken by the Feed roller.
The same procedure of top roller is used for finding the value of maximum shear stress.
Out of the total torque, 15 % of the torque is taken by feed roller, 10.74Nm
Tangential component (Horizontal) of force due to torque
𝑡𝑜𝑟𝑞𝑢𝑒 10743.75
WT= 𝑃.𝐶.𝐷/2 = =429.75N
50/2

𝑊
WR=WNsin 𝜑 = cos𝑇𝜑 sinφ
429.75
WR = sin 20 =156.42N
cos 20
So, Torque on the feed roller = 10.74 N-m

Resultant reaction at ‘b’ = 793.67N
Resultant reaction at ‘f’ = 321.04N
The resultant bending moment at ‘D’ =1984×10 4Nmm
Max. Shear stress = 46 Mpa
Therefore, the feed roller shaft is safe according to shear stress theory.
4.4 Working principle
Our sugarcane juice extraction machine is operated automatically which contains three
rollers. The rollers namely called top, feed, and discharge rollers. The Source of power for
the sugar cane machine is a DC motor. When motor power is on the shaft on the motor is
rotating at the same speed as the motor. The small pulley mounted on the motor shaft also
rotates at the same speed as the motor shaft. A V-belt is used to connect the pulley on the
motor and the pulley on the driving shaft to transmit power or rotational motion. V-blet
reduces the speed of the motor and feeds power to the driving pulley. Then the driving
pulley rotates the driving shaft. The shaft rotates the gear mounted in it. The pinion is
mounted on the driving shaft or shaft on the top roller. We have mounted the pinion on the
driving shaft and gear on the driven shaft to get a higher torque. Then top gear rotates the
discharge gear, and the discharge gear rotates the feed gear. In the same way, the rollers
also rotate with the rotation of the gears. The top roller gets 50% of the total torque, the
46
discharge roller gets 35% and the feed roller gets 15% of the total torque. Then the
sugarcane is feed into the rollers within the chute. The top and feed roller used to squeeze
the cane; the third roller is used to squeeze and discharge the squeeze cane(bagasse) to the
back of the machine. Then the squeezed juice passes through the filter to separate small
bagasse from the juice. At the end of the filter, there will be a valve to control the flow of
the juice. Then the operator will pour the juice to medium and drink.
47
CHAPTER FIVE
5. MANUFACTURING AND ASSEMBLY METHOD
5.1 Manufacturing method
Manufacturing methods or processes are the steps through which raw materials are
transformed into a final product. In the previous chapter raw materials have been selected
for each part. And then the machine parts are design using material properties, material
specification, a different theory of failure, and some parameters taken from previous
design. Then dimension from the design used to manufacture the workshop part. But all
parts are not manufactured in the workshop so they can be purchased from the market by
using dimensions gated from the design. There are different manufacturing processes in
mechanical engineering like shaping, machining, surface finish, joining, and processes
affecting changes in properties. Now in this topic, we will see how to manufacture the
sugar cane machine parts in a workshop by using different machines and machining
operation through a step-by-step procedure.
5.1.1 Manufacturing of roller
In the manufacturing of roller different machining processes are performed. The main
machining process used to manufacture the rollers is turning, facing, drilling, boring, and
knurling which are called turning operations. These operations are performed by using a
lathe machine. Steps for manufacturing of the roller are listed below: -
• The first medium carbon steel rod with a dimension larger than the desired size is
prepared by cutting using a machine tool power hacksaw.
• A small hole more like an indent is created on one face to align the shaft at the
center by using tailstock.
• The turning process comes next, during the turning process cutting tool removes
material from the outer diameter of the rotating workpiece. There are two turning
operations rough and finish. First, we roughly turn the part to decrease within a
short time disregarding the accuracy and surface finish. Then finishing turning
produces a smooth surface finish with accurate dimension.
48
• Drilling operation performs which remove material from the inside of the
workpiece. It will give a hole with a diameter equal to the size of the utilized drill
bit.
• After drilling boring operation is following, in boring operation, the tool enters the
workpiece axially and removes material along the internal surface to enlarge the
existing hole to the desire diameter
• Then in order to increase gripping friction between the roller and the sugar cane a
knurling operation is performed on the roller. This operation produces serrated
patterns on the surface of a part. And we use the most common pattern which is the
diamond pattern.
• Lastly, facing operation is performed. It is used to decrease the length of the roller
to the final size and smooth face surface by removing the thin layer of the material.
5.1.2 Manufacturing of shaft
The shaft manufacturing process is almost the same as the roller. The machining process
includes turning, step turning, facing, and milling. The turning operations are done by the
lathe machine. There is a keyway on the shaft to do this feature we use a milling machine.
The procedure followed to manufacture the shaft is listed below.
• A high carbon steel(50C4) rod is first prepared by cutting with a dimension greater
than the required one. The size is increased to have a comfortable machining
process and a good surface finish.
• The workpiece is then fixed to chuck on the lathe machine then turning operation
is performed. The shaft has a step to produce these feature multiple passes at a
small radial depth of cut is necessary. Step turning creates two surfaces with an
abrupt change in diameter between them. The final future resembles a step.
• The length of the workpiece is slightly longer than the final part so it should be
faced. During the facing, the tool moves along the radius of the workpiece to
produce the desire part length.
• Then keyway on the shaft is done by a keyway milling operation. This operation
can be done either on a specialized keyway milling machine or ordinary mills. The
workpiece is clamped by the fixture, and the keyway milling cutter is used to mill
it layer by layer.
49
5.1.3 Manufacturing of key

Sunk keys have been chosen for our design. They have a rectangular shape. A plain carbon
steels(50C4) rectangular bar is used for the manufacturing of key. The sunk key is
manufactured using a milling machine. The step for manufacturing this key is very simple
it is listed below: -
• First rectangular steel rod is cut to a desired shape.
• The workpieces were fixed on the fixture of the milling machine.
• The machining operation facing is performed on the rectangular bar to give the final
shape and smooth surface finish.
5.1.4 Manufacturing of spur gear
Spur gear is manufactured with the help of cutting. Yet there are many other forming
processes like casting, rolling and forging. We can use either of the processes but for our
design, we use a gear cutting process. Gear cutting is a machining process for creating gear.
The most common gear-cutting processes include hobbing, broaching, milling, and
grinding. Hobbing is the most common method that is utilized in the cutting process due
to its versatility and efficiency. A step-by-step procedure of manufacturing spur gear using
a hobbing process.
• Raw material is brought from a market which is a circular rod within the desired
diameter.
• In sawing process, the material is cut to the size.
• Using a lathe machine, a turning process proceed. In this process, a cut workpiece
is shaped into a gear blank.
• Gear cutting is done with a hobbing machine. The hobbing usually leaves burrs on
the teeth.
• Burrs on the teeth have been removed with a deburring machine to give a clean
and polished look.
• Lastly for gear to have a long lifespan finishing is crucial. Black oxide finish is
performed on the gear in preventing the rust on the spur gear.
Spur gears can be cut or ground by a milling machine or jig grinder utilizing a numbered
gear cutter, and any indexing head or rotary table. The number of the gear is determined
by the tooth count of the gear to be cut. The most common method of cutting the spur gears
50
on a milling machine is by form cutting. This is done by taking a blank gear and rotating a
cutter, with the desired tooth pattern, around its periphery. This ensures that the gear will
fit when the operation is finished. Steps for manufacturing of gear on a milling machine.
• The cutter is formed according to the shape of the tooth.
• The space to be removed between two adjacent teeth by a form milling cutter.
• The cutter is attached to the mandrel and connected to the dividing head.
• The selection of cutter is depending upon the size of the gear tooth and no of teeth.
• Finally, the cutter cut the gear teeth to the desire shape.
5.1.5 Manufacturing of frame and cover
The manufacturing method of frame and cover is made by casting which requires preparing
a pattern that has the same shape as the frame and cover but is constructed from simple
material such as wood, metal, or plastic with slight dimension difference to compensate for
contraction of molten metal during solidification. Then the pattern is placed on sand to
create mold and the gating system is prepared on the mold for the entry of molten metal.
The pattern is removed and molten metal is filled into a molten cavity. After some time,
the molten is cooled then the frame and cover are removed from the mold by destroying
the sand mold.
5.1.6 Manufacturing of bolt and nuts
In the manufacturing of bolts and nuts, there is two manufacturing processes. Those are
forming process without cutting and machining process. Informing process, it includes cold
forming (cold extrusion) and hot forming.
• Forming process
Cold forming
In modern fastening technology, the majority of fasteners are made using the cold forming
procedure. In this procedure, the fastener is formed, usually in multistage processes, by
pressure forging, cold extrusion and reducing, or a combination of these procedures. The
term solid or cold forming was coined for this type of production. This procedure is usually
used for large quantities, because, from an economic aspect, it is the most rational method.
Hot forming
This production method is used mainly to manufacture large diameters starting with
approx. M27, and longer pieces starting from approx. 300 mm. Besides, there are parts
51
cannot be produced using cold forming because of the very small volumes, or because of
a very high degree of forming. With this procedure, the input material (usually bars) is
heated wholly or partially to forging temperature. This heating up enables even
complicated geometries or very high degrees of forming to be realized.
• Machining
Machining is usually understood as processing steps such as turning, milling, grinding, or
reaming. The most common method concerning fasteners is turning. During turning, the
required contour of the component is cut from the input material using a turning tool. The
diameter of the input material depends on the largest diameter of the component. Usually,
bars with a length of up to 6 m are used.
5.1.7 Manufacturing of bearing
In ball and roller bearings, the rolling elements and the races are subjected to high local
stresses of varying magnitude with each revolution of the bearing, therefore the material of
the rolling element (i.e., Steel) should be of high quality. The balls are generally made of
high carbon chromium steel. The material of both the balls and races are heat-treated to
give extra hardness and toughness. The rollers are manufactured by hot forging on
hammers from steel rods. They are then heat-treated, ground, and polished. The races are
also formed by forging and then heat-treated, ground, and polished.
5.1.8 Manufacturing of pulley
A v-pulley manufacturing process includes the following steps:
• Forming a pulley: integrally forming a cylindrical pulley blank.
• Machining v-belt grooves: Cutting the external surface of the pulley blank to form
a plurality of V-belt grooves matching a V-belt.
• Fine machining: cutting the external surfaces of the pulley blank and the side
surface of the belt groove, and cutting the machining allowance.
• Shoot blasting: placing the pulley in a shot blasting machine to form a rough shot
blasting layer on the side surfaces of the V-belt grooves.
5.2 Assembly method

Sugar cane juice extraction machine is a combination of different parts. These parts should
have to be assembled to function properly. The assembly processes of the sugarcane
extractor machine start with the assembly of bearing in the frame by a press-fit after that
52
the shaft is assembled in the bearing on one half of the frame. Then the key assembled on
the shaft keyway and rollers which are a hollow shaft are assembled on the solid shaft and
the key. Then the other half of the frame is assembled to the first half including shaft, key
roller, and bearing. All the gears assembled with the key and shaft in their appropriate
position. The first gear assembled on the driving shaft. The second two gear assembled on
the first driven shaft. The fourth gear assembled on the second driven shaft. A key is
assembled between the gear hub and the shaft.
The bigger pulley is mounted on the load shaft with a key in between them. The smaller
pulley is assembled on the motor shaft which is used as a power transmission medium
between the motor and the bigger pulley. The motor and the driving shaft are connected by
using a V-belt which is mounted on the bigger and smaller pulley. The cover is assembled
to the hole part of the machine for protective measure and bolted with the frame. Finally,
the Filter is placed underneath the rollers to clarify the juice.
5.3 Maintenance of the machine

To keep our equipment running optimally and to increase the life span of each part daily
maintenance on our sugarcane machine is necessary. Maintenance of essential parts that
need periodic maintenance is discussed below in detail.
5.3.1 Maintenance of roller
At the end of the day of operation, we have to remove the rollers from the machine. And
wash them with warm water and a soft brush. Also, if the rollers are sticky then we can
soak them in hot water with a little soap for about 30 minutes. Then after they dry, we
replace them with the machine. This will help for decreasing the wear of the rollers from
corrosion. This in turn increases the life range of the rollers. This is called preventive
maintenance.
But when the teeth of the roller are worn out during a long period, we have to replace them
with a new one because it will decrease the efficiency of the machine. If they are also
showing any crack they have to be changed before they break down completely and ruin
the whole machine. This maintenance is called corrective maintenance.
5.3.2 Maintenance of spur gearbox
There should have to regular visual inspections of spur gearboxes. Look for oil leaks on
the input and output shafts, and discoloration of the paint that might indicate overheating.
53
Damage caused by overheating is usually irreversible, the only way to repair it is to replace
some component, so we have to keep an eye on this.
Visually inspect the spur gear after every run for signs of wear or small debris lodged
between the spur gear's tooth profile. Small stones can be removed from the gear with a
hobby knife, but if the spur gear show signs of excessive wear replace the gear before
continuing to run the machine.
Try to keep them as clean as possible to avoid the potential ingress of contaminants into
the unit and aid visual inspections. Dust and dirt covering a gearbox can also contribute to
overheating so brush them clean regularly.
Routine lubrication per the given specifications is essential. Make sure we are using the
right lubricant with the correct additives for our application.
5.1.3 Maintenance of V-belts and pulley
Most V-belt drives fail due to due to improper installation and maintenance. So good
maintenance practices ensure longer belt life, lower maintenance costs, longer drive
component life, increase productivity, reduce downtime and soon. But well designed and
properly installed V-belt drives are without question the most reliable, trouble-free means
of power transmission available. In general, except for an occasional re-tensioning, they
will run year in and year out without maintenance. However, some do require periodic
inspection and maintenance, both while the drive is running and while it is stationary.
5.1.4 Maintenance of Pulley
Before installing a new set of belts, the pulley walls should always be checked for wear,
rust, damage, or porosity. Through continuous use, the pulley walls become dished out,
which reduces the ability of the belt to wedge in the groove.
Pulley wear is much less apparent than belt wear, yet equally critical. Generally, when
pulley sidewall wear exceeds 0.06mm when measured with a feeler gauge and a straight
edge or pulley profile gauge, the pulley should be replaced. In another way, we can also
replace worn pulleys after 3 belt replacements.
5.1.5 Maintenance of belt
Proper alignment is essential for long belt life. Check belt alignment whenever we maintain
or replace belts or whenever you remove or install pulleys.
54
We have to check for loose belts by putting our fingertips in a sheave groove after the drive
shutdown. If sheave is so hot, we cannot comfortably keep them there, the belts have
probably been slipping. Then we have to check for adequate tension and/or worn sheaves.
When we re-tension the belt, it shouldn’t have to be over tensioned because it will shorten
the belt and bearing life.
Inspect sheaves often keep all sheave grooves smooth and uniform. Burrs and rough spots
along the sheave rim can damage belts. Dust, oil, and other foreign matter can lead to
pitting and rust and should be avoided as much as possible.
Belts have to keep clean dirt and grease to reduce belt life. Belts should be wiped with a
dry cloth occasionally to remove any build-up of foreign material. If the belts have been
splattered with grease and/or oil, clean them with methyl chloroform or soap and water.
5.1.6 Maintenance of bearing
Bearings have to keep dirt-free, moisture-free, and lubricated. Water will rust the bearing
and dirt will destroy the smoothness of the super finish on the bearing races, and increasing
friction.
We have to clean bearings when they become dirty or noisy with the most environmentally
friendly cleaner, we can find that is suitable for dissolving oil, grease, and removing dirt
from the steel. Citrus based cleaners can work, but they tend to leave behind a slight
residue. If we use this water-based cleaner like a citrus cleaner or a detergent, be sure to
dry the bearings. Immediately and then re-coat them with lubricant to prevent rust.
Do not add oil to dirty bearings. It will not clean the bearing but merely flush the existing
dirt further into the bearing. It may seem like they roll faster initially, but in reality, are
only spreading the dirt around, and it will still be there to ruin the high precision rolling
surfaces of the bearings. Always Clean your bearings before re-lubricating them.
Table 5. 1 Maintenance of sugarcane extraction machine

S.N Part Types of maintenance
Preventive Maintenance Duration Corrective Maintenance
performed performed
1 Roller ✓ wash them with After ✓ Replace if
warm water and a every there is a
soft brush operation break, and
for 30 min worn out
55
2 Spur ✓ o Check oil Regularly ✓ Replace if

gearbox leak there is
o Check abrasive
Discoloration wear
o Proper
Lubrication
3 Pulley ✓ Check pulley wall When a ✓ Replace if
for wear, rust, and new belt the wear
damage replaces exceeds
0.06mm
4 Belt ✓ o Check belt During ✓ Replace
alignment installation when the
o Check loose and after belt is worn
belt every out
o Inspect drive
sheave
o Make clean
5 Bearing ✓ keep dirt-free, when they ✓ Replacement
moisture-free, and become every 5
lubricated dirty or years
noisy
6 Shaft ✓ Lubrication ✓ Replace is
Shaft and alignment they break
checkup down.
56
CHAPTER SIX
6.COST ANALYSIS
6.1 Cost analysis
The cost of the sugarcane juice extraction machine is analyzed by considering the cost to
purchase raw material used to manufacture different parts of the machine and the
contingency cost. The cost of raw material for each part is obtained from Alibaba.com.
Since the amount of money is given by USD per ton of material, we have used some
techniques to obtain the amount of money needed for the exact size of the component.
✓ First step- conversion of a unit of money from USD/ton to birr/kg.
39.08
𝑋=𝑍× 1000
Where Z= amount of money by USD per ton

X = amount of money by birr/kg
✓ Second step- finding the exact mass of the component
𝜌=𝑚𝑉
From eqn, 𝑚 = 𝜌 × 𝑉
Where m= exact mass of the component
V= volume of the component
𝜌=density of material
✓ Third step –Cost estimation
Multiplication of results of equation 1 and 2
𝐶=𝑚×𝑋
✓ Fourth step- finding the grand total cost
Cost analysis for roller
• Cost of medium carbon steel 45C8, 575 kg/birr
• Dimension of roller, r1= 0.05m, r2 = 0.0125m, h= 0.15m
• Density of medium carbon steel, 7850 kg/m3
39.08
From eqn, 𝑥 = 575 × = 22.471 𝑏𝑖𝑟𝑟/𝑘𝑔
1000
V = 𝜋ℎ(𝑟1 2 − 𝑟2 2 )= 𝜋 × 0.15(0.052 − 0.01252 )= 1.1045×10-3

𝑚 = 𝜌 × V = 7850 × 1.1045× 10-3 = 8.67 kg
57
𝐶 = 𝑥 × 𝑚 = 22.471 × 8.67 = 194.82 birr

Cost analysis for shaft
• Cost of high carbon steel rod 50C4, 575 USD/ton = 22.471 𝑏𝑖𝑟𝑟/𝑘𝑔
• Dimension of shaft, r= 0.00125m, h= 0.5 m
• Density of high carbon steel, 7850 kg/m3
V = 𝜋ℎ𝑟 2 = 𝜋 × 0.01252 ×0.5 = 2.45 ×10-4
𝑚 = 𝜌 × V = 7850 × 2.45 ×10-4 = 1.93 kg
𝐶 = 𝑥 × 𝑚 = 22.471 × 1.93 = 43.29 birr
Cost analysis for key
• Cost of high carbon steel rectangular bar 50C4, 575 USD/ton= 22.471 𝑏𝑖𝑟𝑟/𝑘𝑔
• Dimension of key, 8×7×40 mm
V = b×h×l = 8×7×40 =2240mm3= 2.24×10-6m3
𝑚 = 𝜌 × V = 7850 ×2.24×10-6= 0.0176 kg
𝐶 = 𝑥 × 𝑚 = 22.471 × 0.0176 kg= 0.395 birr
Cost analysis for gear
• Cost of plain carbon steel rod 50C4, 575 USD/ton = 22.471 𝑏𝑖𝑟𝑟/𝑘𝑔
• Dimension of gear, rg=0.065m, rs=0.025m, h= 0.02m
• Dimension of pinion rp=0.027m, rs=0.025m h=0.02m
Vg = 𝜋ℎ(𝑟𝑔 2 − 𝑟𝑠 2 )= 𝜋 × 0.02(0.0652 -0.0252) = 2.262×10-4
Vp =𝜋ℎ(𝑟𝑝 2 − 𝑟𝑠 2 )= 𝜋 × 0.02(0.0272 -0.0252) = 6.535×10-6
𝑚g= 𝜌 × Vg= 7850 ×2.262×10-4= 2.061kg
𝑚p= 𝜌 × Vp= 7850 ×6.535×10-6= 1.776kg
𝐶g = 𝑥 × 𝑚g = 22.471 × 2.061=46.32 birr
𝐶p = 𝑥 × 𝑚p = 22.471 × 1.776=39.91birr
Cost analysis for bolt
• Cost of high carbon steel rod 60C4, 470 USD/ton = 18.368𝑏𝑖𝑟𝑟/𝑘𝑔
• Dimension bolt, M8×1.25 mm, Do = 13mm, L=50mm
58
V = 𝜋ℎ𝑟 2 = 𝜋 × 0.0052 ×0.05 = 3.926 ×10-6

𝑚 = 𝜌 × V = 7850 ×3.926 ×10-6= 0.031 kg
𝐶 = 𝑥 × 𝑚 = 18.368×0.052 = 0.566 birr
Cost analysis of pulley
The cost of the pulley which is made up of cast iron for V belt type is the US $2-10/piece.
So, we will take the average value which is $6/piece. When it is changed into birr 6×39.08=
234.48 birr. For the design we need two pulleys it costs 468.96 birr.
Cost analysis of V-belt
• Cost of V-belts is $0.01/ inch, 0.398birr/inch.
• Dimension of V-belt, 1m = 39.37 inch
Cost analysis of bearing
• The cost of bearing is the US $0.02-0.09/ piece
• Dimension, 47mm outer and 25mm inner
We will take the average value which is $ 0.055/ piece. When converted to birr it is
0.055×39.08= 2.15 birr/ piece.
Cost analysis for frame
• Cost of frame,18.368birr/kg
• Dimension of frame, height=673mm, width=10mm, depth=310mm
• The density of low alloy steel, 7850 kg/m3
V = h×w×d= 0.673×0.01×0.31 = 2.0863×10 -3m3
𝑚 = 𝜌 × V = 7850 × 2.0863×10 -3 = 16.377
𝐶 = 𝑥 × 𝑚 = 18.368 × 16.377= 300.82 birr
Cost analysis of motor
• The cost of a permanent magnet DC motor is the US $8.00 -40.00 / piece
We will take the average value which is $ 24 / piece. When converted to birr it is 24
×39.08= 937.92 birr/ piece
59
Table 6. 1 Cost analysis of the sugarcane juice extractor

S.N. Materials Quantity Unit cost(birr) Total
cost
1. . Roller 3 195 585
2. Shaft 5 130 650
3. Key 10 0.5 5
4. Gear Gear 4 47 188
Pinion 1 46 46
5. Bolt 16 1 16
6. Pulley 2 467 934
7. V-belt 1 16 16
8. Bearing 9 3 27
9. Frame 1 1 301
10. Motor 1 940 940
Total 3708
Contingency cost = CT x 10%
Contingency cost = 370.8 birr
Grand total cost of sugarcane juice extraction machine= Contingency cost + total cost
= 370.8+3708
= 4078.8birr = 4080birr
60
CHAPTER SEVEN
7. RESULT AND DISCUSSION
7.1 Result
Results obtained from the detail design for each part are represented in the form of a
table.
The crushing roller dimension obtained from the detail design is tabulated in table 5.1
below
Table 7. 1 Result of crushing roller

S.N. Roller Result
1. Diameter Outer diameter  100mm
Inner diameter  25mm
2. Length, l 150mm
3. Nipple angle, θ 20º
4. Clearance, L Min 26mm
Max 25mm
5. Thickness, t 5mm
6. Weight, W 11.56N
7. Crushing force, FC 100N
8. Crushing torque, TC 5Nm
9. Speed, N 200rpm
10. Angular velocity, 𝜔 21rad/s
Pulley and V-belt dimension obtained from the detail design is tabulated in table 5.2
below.
Table 7. 2 Results of pulley and V-belt

S.N. Pulley and V-belt Result V-belt Result
1. Power shaft diameter, D1 100mm Belt length 1m
2. Load shaft diameter, D2 200mm Belt thickness, t 8mm
3. Center distance between 175mm Belt width, w 13mm
the pulley, C
4. The angle of contact, θ 2.6rad/s Belt T1 248 N
tension, T2 29.2 N
The shaft and key dimension obtained from the detail design are tabulated in table 5.3
below.
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Table 7. 3 Result of shaft and key

S.N. Shaft Result Key Result
1. Diameter, d  25mm Dimension, 8×7×40 mm
b×h×l
2. Length of shaft 500mm Key way depth 4mm
Spur gear dimension obtained from detail design is tabulated in table 5.4 below.
Table 7. 4 Result of spur gear
S.N. Pinion Gear
1. Module 2
2. No of teeth 25 63
3. Pitch circle 50mm 126mm
diameter, dp
4. Diametrical 0.5mm 0.5mm
pitch, pd
5. Outside 54mm 130mm
diameter, Do
6. Nominal 88mm
center
distance
Bearing selected for the design using shaft diameter from the table is listed in table 5.5
Table 7. 5 Result of bearing
S.N. Bearing Result
1. Bearing N.O. 16005
2. Outer diameter 47mm
3. Inner diameter 25mm
4. Width 8mm
Max Shear stress values developed in each material is calculated for the three rollers is
listed in table 5.6 below
Table 7. 6 Result of maximum shear stress (working) values of roller
Roller Max. Shear stress (By
Analytical) MPa
Top roller 158
Discharge roller 75
Feed roller 46
7.2 Discussion
Design is started by measuring 4 different sizes of sugar cane to obtain the maximum and
minimum size of cane that can be crushed by the machine. It helps us to get the mass and
dimension like diameter and length of the cane which is useful for further design. From
62
measured value the maximum diameter of the cane is 60mm and the minimum diameter is
33mm. Design consideration taken are the diameter of roller is 100mm, and it contain 3
rollers and length of the roller is 150mm. thickness and weight of roller calculated.
Crushing force of roller is calculated by using rapture force of sugarcane and factor of
safety which is 100N exerted by the roller on sugarcane to crush it. Using this force, the
torque and speed of roller is calculated. Then the value of torque used to calculate the motor
power. From calculation a motor which have 2HP and 1000rpm is selected. After that using
this result and different criteria motor type is selected. Selected motor type for our design
is permanent magnet DC motor.
Next pulley and V-belt is calculated which is tabulated in table 7.2. There are two pulleys
driven and driving pulleys. Their diameter, center distance, angle of contact, belt length,
belt tension is calculated by using different formulas and standards taken from table.
Shaft and key are design next. Shaft diameter is calculated based on strength and rigidity
formula. Two result of shaft diameter is obtained which are 25 and 14 mm, but for our
design we select the larger value of the shaft. Key is also designed by considering crushing
and shearing stress. Then stress analysis is done for the shaft and key to check if the
material used for the parts is safe. And the allowable shear stress value for shaft and key is
165 and 330Mpa respectively. The calculated stress value or working stress for shaft and
key is 49.27 and 297 Mpa respectively which is less than the allowable stress which is safe.
Spur gear box is design is preceded next. First, we select the type of gear train. For gear
ratio less than 10:1 simple gear train is used. Our design gear ratio is 2.5:1, then we select
a simple gear train for the spur gear box. Pinon and gear design by taking some assumption
like pressure angle 20, and module 2. Therefore, to avoid interference between the teeth
the minimum pinion teeth should be less than 18. For our design we select a number of
teeth for the pinion is 25. Based on this information another dimension of the pinion is
calculated which is tabulated in table 7.4. Also gear teeth no is calculated by using pinion
teeth no with relation to speed ratio of the gear. With the same procedure the dimension
for the gear is calculated. Stress analysis is done on the tooth of the gear which is further
useful for stress analysis of roller shaft and selection of bearing. Bearing is selected based
on the shaft diameter and radial and axial force developed in the tooth gear.
63
Frame and bolt are also designed. The frame has a dimension of width 10mm, depth
310mm and height 347mm, and bolt dimension design and diameter M6×1 is selected. The
stress developed on the frame is calculated which is 106Mpa which is less than the
allowable shear 165Mpa. Then the design is safe according to maximum shear stress
theory.
Analytic Stress analysis is also done on the crushing roller. We checked the failure of
material according to maximum shear stress theory. The results are shown in table 7.6 as
it seen the working shear stress for each crushing roller is less than the allowable shear
stress then our design is safe to operate.
64
CHAPTER EIGHT
8. CONCLUSION AND RECOMMENDATION
8.1 Conclusion
Sugarcane crushing and squeezing machine with a three-roller driven by a permanent
magnet DC motor with a capacity of 2 HP and 1000rpm is designed with the capability to
squeezes any sugar cane with a diameter greater than 30 mm. The extractor of sugar cane
juice has a unique design in a way that it can dumb vibration induced from the motor as
well as compactness and aesthetics and also the flexibility of its function by providing a
hallowed space on the bottom part of the cover either for storage of raw cane or for the
accumulation of the juice in large amount as per the need of the user. The machine
possesses simplicity in operation and maintenance, as well as being affordable with low
manufacturing, running, and maintenance costs. The interaction between contaminants and
the extracted juice is considered negligible with the supplied isolation of the extraction
process from the environment. Due to the electric transmission motor used, the rollers
worked without being stuck independent of the sugar cane juice. If it is commercialized,
the machine will create awareness about the existence of sugarcane juice and improve
traditional and tiresome cane consuming method and could go a long way in solving the
problem of sugar-cane juicer machines.
8.2 Recommendation
For further upgrading the machine the following modifications are recommended.
• In areas where contact is made between the juice and the side plate which holds the
rollers of the machine when used industrially, stainless steel can be used. This
would improve the machine's hygiene.
• A sieve can be used to collect small bagasse particles which can be drawn with the
extracted juice via the juice chute or exhaust.
• A cutting section to cater can be constructed and attached to the machine to
complement its operation and scrap the sugar cane before the juice is extracted.
• An adjustment for the crushing mechanism can be used vary the gap between the
rollers and thus vary in crushing and squeezing sugarcane with different diameters.
• Use of solenoid valve to control the flow of juice and to prevent wastage of juice.
65
REFERENCE
1.https://en.wikipedia.org/wiki/Sugarcane
2.https://www.researchgate.net/figure/The-world-top-10-sugarcane-production-countries
in-2013-for-their-cane-production_tbl1_283959617
3. https://en.wikipedia.org/wiki/Sugarcane
4. https://en.wikipedia.org/wiki/Sugarcane_juice
5. https://www.pinterest.com/pin/648377677577171491/
6. http://nutrition.indobase.com/articles/sugarcane-juicenutrition.php
7. https://en.wikipedia.org/wiki/Sugarcane_juice
8.Ambare, R., Gunjal, R., Chavan, O., & Hande, V. (2019). Design and development of
sugarcane juicer machine. 978, 112–114.
9.Priya, D. K., & Lakshmi, Y. V. (2018). Sugarcane Juice Vending Machines and
Vendors-Problems and Prospects. International Journal of Science and Research,
3(April), 3071–3074. www.ijsr.net
10.Makinde-Ojo, A. M. (2010). Project Work on The Improvement of the Fabrication
and Testing of a Sugarcane Juice Extractor for the Cottage Industry by Makinde-
Ojo, Ayoola Macjay Matriculation Number 2005 / 0203
11. Olaoye, J. O. (2011). Development of a sugarcane juice extractor for small scale
industries. Journal of Agricultural Technology, 7(4), 931–944. http://www.ijat-
aatsea.com
12. Olaniyan, A. M., & Babatunde, O. O. (2012). Development of a small scale
sugarcane juice extractor using a screw pressing system. Advanced Materials
Research, 367, 699–709. https://doi.org/10.4028/www.scientific.net/AMR.367.699
13. Rumah, U. J., & Mohammed, I. L. (2015). Design of an improved short rollers sugar
cane juice extractor machine. 7(October), 1–7.
14.Piacente, F. J., Silva, V. D. C., & Biaggi, D. E. (2016). Sugar cane juice extraction
innovation : technological prospecting study about diffuser and crush process.
POMS 27th Annual Conference Innovative Operations in an Information and
Analytics-Driven Economy, 6-9 May 2016, 1330–1340.
15.Raji, N. A., Adedeji, K. A., Olaleye, J. O., & Adele, F. A. (2019). Design and
fabrication of tiger nut juice extractor. Journal of Applied Sciences and
Environmental Management, 23(3), 563. https://doi.org/10.4314/jasem.v23i3.29
16.Ugye, R., & Kolade, O. A. (2019). Design Parameters for a Sugar Cane Extractor.
American Journal of Engineering Research (AJER, 8, 118–123. www.ajer.org
66
17. Wills, B.A. and Napier-Munn, T. (2006). Wills’ Mineral Processing Technology-
An Introduction to the Practical Aspects of Ore Treatment and Mineral Recovery.
Seventh Edition. Amsterdam: Elsevier Science and Technology Books. P450.
67
APPENDIX
Appendix 1
Comparison different types of motor.
Appendix 2
standard v belt dimension according to IS: 2494-1974
68
Appendix 3
Dimensions and static and dynamic load capacities of single-row deep groove ball
bearings
69
70

Design of Sugar Cane Machine

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Design of Sugar Cane Machine

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[DESIGN OF SUGARCANE JUICE EXTRACTION MACHINE]

Nahom Tadesse 0970/06

Mihret Tegenu 0800/08

Rediet Zeleke 0933/08

A Thesis Submited in Partial Fulfillment

of the Requirments for the Degree of

(Lecturer, Mechanical Engineering Department )

DEPARTMENT OF MECHANICAL ENGINNERING

COLLEGE OF ELECTRICAL AND MECHANICAL ENGINEERING

ADDIS ABABA SCIENCE AND TECHNOLOGY UNIVERSITY

ADDIS ABABA SCIENCE AND TECHNOLOGY UNIVERSITY

COLLEGE OF ELECTRICAL AND MECHANICAL ENGINEERING

MECHANICAL ENGINNERING DEPARTMENT

[Design of Sugarcane Juice Extraction Machine ]

Submitted by: Signature Date

Approved by Signature Date

Submitted by: Signature Date

4.2.1 Design of roller ................................................................................................ 25

6.1 Cost analysis ........................................................................................................... 57

1.2 Statement of the problem

1.4 Significance of the study

1.5 Scope of the project

4.1.1 Selection of material for roller

Table 4. 1 Property of materials used for the design of roller

Table 4. 2 Weight of properties used for the design of roller.

The sum of thermal conductivity of three materials is given by

Table 4. 3 Comparison of materials used for the design of roller

Thermal 2 0.46 0.92 0.39 0.78 0.149 0.299

Table 4. 4 Properties of materials used for the design of the shaft

Table 4. 5 Comparison of materials used for the design of the shaft

Table 4. 6 Properties of material used for the design of the cover

Elongation (in 50mm) 15 18

Table 4. 8 Properties of material used for the design of the frame

High carbon Free cutting Alloy steels

Table 4. 10 Weightage of points for comparison of keys

Table 4. 11 Comparison of saddle key and sunk key

Table 4. 12 Selection of power transmission method

No Criteria Types of mechanical drive

1 Velocity Not Not constant Not constant Constant

2 Power Low Good High High

3 Slip Slippage Comparatively Not positive No-slip,

7 Noise More Less noise Higher noise Have a

Table 4. 13 Comparison of the spur gear and helical gear

Properties Types of gear

Table 4. 15 Selection of gear for sugar cane machine

Table 4. 16 Weightage of points used to select the bearing

Table 4. 17 Comparison of different types of bearing

4.2 Design calculation

Table 4. 18 Measured value of different size sugar cane

4.2.1.2. Thickness of roller

The weight of the crushing roller is estimated from equation (3).

𝜋0.12 𝜋0.0952 𝜋0.0952

The crushing force on the roller is expressed as given in equation 5.

The crushing torque on the roller is expressed as given in equation 6.

4.2.2.2 Selection of motor type

Table 4. 19 Comparison of dc motors

Top width(b)= 13mm

Design of driving pulley

Where D1 =diameter of the driving pulley

4.2.3.3 Design of center distance between the pullies

Where 𝜃 = angle of lap for driving pulley

4.2.4.2 Design of shaft based on rigidity