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FINAL REPORT ON
SUBMITTED BY:
ABHISHEK K. KARN [32131]
AMRIT K. YADAV [32143]
JENISH NANICHA SHRESTHA [32136]
May 2022
PROJECT EVALUATION
By
This is to certify that I have examined the above Project report and have found that it
is complete and satisfactory in all respects, and that any and all revisions required by
the project report examination committee have been made.
May 2022
ii
ACKNOWLEDGMENT
It really is a pleasure to thank the wonderful folks at Kathmandu University for their
unconditional support from the start of our initiative. First and foremost. We would like
to express our gratitude to Kathmandu University's Department of Mechanical
Engineering for providing us with technical assistance in the completion of our project.
We may not be able to finish this design of our project without it.
Keeping in mind the prior suggestions, we would like to convey our heartfelt
appreciation to Er. Jahir Ahmad Jibran for guiding us through the entire project. We
also owe it to our project coordinator, Er. Malesh Sah, to convey our gratitude for his
leadership.
We would like to express our deepest gratitude to the many readers of our project report,
who are the most significant critics and commentators. We welcome constructive
criticism and recommendations that will assist us in improving our performance in the
future.
It is our pleasant mood to express the deepest appreciation to all who were directly
and/or indirectly involved in the successful completion of our project's design.
iii
TABLE OF CONTENTS
CHAPTER 1: INTRODUCTION..................................................................................... 1
1.1 Background ............................................................................................................ 1
1.2Objectives ................................................................................................................ 2
1.3 Scope ...................................................................................................................... 2
1.3 Significances .......................................................................................................... 3
1.4 Limitations.............................................................................................................. 3
1.5 Challenges .............................................................................................................. 3
REFERENCES ............................................................................................................... 26
ANNEX .......................................................................................................................... 27
iv
LIST OF FIGURES
v
LIST OF TABLES
Table 1 Component of mango cutting machine ........................................................... 19
Table 2 Gantt Chart ...................................................................................................... 23
Table 3 Budget estimation............................................................................................ 24
vi
ABSTRACT
The main objective of this project is to explain the basic considerations that are included
in the design of the ‘MANGO CUTTING MACHINE’. We have designed a simplified
mango cutting machine. In this report, all design parameters are calculated at maximum
efficiency. These parameters included ac motor power, blade speed, diameter of pulley,
frame length, shaft diameter, and plummer diameter. We have designed the parts using
the SolidWorks design tool. Mangos are used for making juice, mango pickle, etc. To
make mango pickle, we have to cut the mangos into cubic pieces. And the mangos are
cut by a manual cutting system by hand with a knife. Manual cutting systems are not
safe because they lead to injuries like cutting workers' hands and fingers. It is also
difficult to cut the mango because of the presence of its hard seed.
In the present work, we have designed the mango cutting machine, which overcomes
the drawbacks of the previously existing machines. To cut the mangos into cubic pieces,
the blades are fixed to the inner wall of the cover and to the rotating shafts. The rotating
shafts are mounted with the three covers, one upon the other, in which the 2nd shaft is
perpendicular to the 1st and 3rd shafts by using bearings. The power from the motor to
the first shaft is transmitted by using pulleys and belt drive. To obtain the required speed
of the shaft, different diameters of pulleys are mounted in the motor and on the shaft.
The power from the 1st shaft to the 2nd and 3rd shafts is transmitted by using pulleys
and belt drive.
vii
CHAPTER 1: INTRODUCTION
1.1 Background
Mango (Mangifera indica L.) is a drupe, or stone fruit, which means that it has a large
seed in the center. It is also known as the "King of Fruits" in several parts of the world.
Mango is a fruit that has been grown for over 4,000 years in Southeast Asia. There are
hundreds of different mango varieties, each with their own flavor, shape, size, and color.
This fruit is not only tasty, but it also has a balanced nutritional profile.
Mango is one of the most important fruits in the world, and it is grown in over 100
countries at both tropical and subtropical latitudes, primarily in Asia. India is a leading
mango-growing country and produces about 65% of the world’s total mango production.
It is considered the most important fruit, covering 35% of the area and 28% of the total
production of fruits in the country. In India, the area under mango cultivation was about
2500 ha and about 1800 ha. About 4 thousand metric tons of mango were produced
during the year 2012-13[1]. According to the Department of Agriculture, the country’s
annual requirement of mangos is 277,000 tonnes. There is a shortfall of 6,000 tonnes
which is made up by imports from India. Mango farming is done on 47,000 hectares.
Siraha and Saptari are the major mango producing districts in the country, followed by
Mahottari, Kapilvastu, Dhanusha, Sarlahi, and Rautahat. Siraha produces 35,000 tonnes
of mangoes on 5,000 hectares while Siraha produces 20,000 tonnes on 5,000 hectares.
"Around 20 districts have high potential for mango farming. [2]
So, it is fundamental to automate these tasks by creating proficient machines that can
reduce the handling time as well as the cost of activity and make the cycle cleaner. The
mechanical activity of cutting and 3D-shape cutting of crude mango is favorable as it
includes more exact cutting and 3D-cube cutting than manual cutting. It diminishes
natural product harm and improves its effectiveness and exactness. Notwithstanding,
just a restricted amount of work has been done and distributed on the advancement of
cutting and 3D shape cutting machines. As a result, the current investigation was
embraced with explicit objectives to fabricate a proper, effective crude mango slicer and
a 3D square shaper for motorizing the pickle preparing industry. [3]
1
Figure 1 Mango and mango cubes
1.2Objectives
The major objective of our project is:
• To design and fabricate mango cutting machine to cut the mangos into cubic
pieces which would be used for the purpose of mango pickles
1.3 Scope
• This mango cutting machine can be used in a small-scale mango pickle
manufacturing facility to produce large quantities of mango pickles
• It can also be used to cut vegetables and fruit other than mangoes
2
1.3 Significances
The production of a large quantity of mango pickles means an increase in the generation
of income. Such a machine can also be used in the houses of the local people to save
time and effort. It can also be installed in hotels to avoid laborers’ uncertainty. Besides
this, such a machine can also be used to cut other types of fruits and vegetables.
1.4 Limitations
The dimensions of our designed product do not exactly match those of the product
available on the market. There is complexity in the designing and fabrication process of
the machine in Solidworks. This machine carries a significant amount of weight. As a
result, it is not easily transportable, and we may encounter difficulties while moving it
from one location to another. If one of the blades in any shaft is damaged during the
operation, it is difficult to remove the welded damaged blade. The sliced pieces of
mango seed must be manually removed from the collection unit.
1.5 Challenges
Drilling holes for the nuts and bolts in the hefty frame of this machine was a challenging
task. The process of welding the blades into the shafts takes a long time. The plummer
blocks' diameter did not match that of the hollow shaft on which the blades were
mounted. As a result, we had to join a solid shaft to each side of the hollow shaft, whose
diameter was made identical to the plummer diameter using a lathe machine. It was
difficult to bend the GI sheet into the shape of a hopper It was tough to get the belt
between the pulley and the motor in the right place.
3
CHAPTER 2: METHODOLOGY
The main switch is turned on and power is supplied to the 3-phase motor. This transmits
power to the first cover shaft. With the help of the first cover shaft, the power is
transmitted to the 2nd and 3rd cover shafts to cut the mangos into pieces at different
stages. [5]
In the first cover, the mango pieces come from the hopper, and the mangos fall on the
rotating blades and then onto the collector. The mango will be cut into rectangular pieces
due to the shear force between the blades and the mango. And simultaneously, those cut
mango pieces move to the second cover. On the 2nd cover, the cut mango pieces come
from the 1st cover and fall on the 2nd cover. The shaft with the moving blades again
cuts those pieces with the same process but in different sizes according to the blades
arranged on the shaft. And then, simultaneously, those mango slices move to the 3rd
cover.
And in the third cover, the mango slices come from the second cover and fall on the
moving shaft. The pieces cut in the second phase are again cut into smaller pieces
compared to the second and first ones. Finally, the cut mangoes of the required size are
collected in the base collector and taken out for use.
4
Figure 2 Mango cutting machine [1]
The above figure is the reference design of mango cutting machine, in which
pulleys are used to transmit power from one shaft to another. A total of 3 shafts are used.
A bevel gear is used in the machine's second row to transfer mechanical energy or shaft
power between shafts that intersect at an angle of 90 degrees. Three rows of cutting
blades are used to cut the mangoes into different sizes. Plummer blocks are used to hold
the shaft.
• Feeding hopper
It is a container which is fixed at the top of the machine into which mango is poured at
intervals and from which it is regularly fed to the cutting system. It is made from mild
steel sheet measuring 155 mm x 75 mm for easy discharge.
5
Figure 3Feeding Hopper [6]
• Cutting blade
The cutting blades are fixed to the shaft and rotate along with the shaft. They are made
from hardened stainless steel and have a 250 mm length and a 100 mm height mounted
on the shaft. The thickness of the blade was 3 mm to bear the cutting pressure of mango
slices. It cuts the mango into pieces of different sizes. There are 30 blades in the mango
cutting machine.
• Collecting unit
The collecting unit is used to collect the cubical mango pieces discharged from the
inclined hopper and is provided below the cutting unit. The lower collector and the base
collector both have the same dimension of 78 cm x 78 cm. The base collector has a
height of 25 cm. These collectors are made from stainless steel.
6
Figure 5Lower collector
7
Figure 7Single phase ac motor[6]
Figure 8Pulley
8
• Bevel gear
Bevel gears are gears where the axes of the two shafts, i.e., the 1st and 3rd shafts,
intersect and where the tooth-bearing faces of the gears themselves are conically shaped.
Bevel gears are most often mounted on shafts that are 90 degrees apart. The internal
diameter of this bevel gear is 50 mm. It is made from hardness stainless steel.
• Plummer block
Plummer block housings can be used with high-capacity spherical roller bearings or
self-aligning ball bearings. They are manufactured from high-strength cast iron as
standard. The housings have a re-lubrication facility and can be used with either oil or
grease lubrication. There are 8 plummer blocks used in this machine, each with a
diameter of 50 mm. They are used to provide support for the rotating shafts.
9
2.3 Study Design
• Literature review
• Consult with supervisor and coordinator for the budget estimation and
materials
• Identify and finalize the required tools
• Collect the required tools and materials
• Manage the materials in correct shape and size
• Fitting of frame smoothly and creatively
• Fabrication
• Test the product at the University
• If any defect on product, correction of design and product
First, we conducted a literature review on existing mango cutting machine models and
the mango fruit itself. For this, we chose relevant research publications and assessed
them on a technical level. Then we devised a plan for how the current machines work
and what steps could be taken to improve their efficiency. We completed the necessary
calculations for this machine and began designing a 3D model of each component in
Solidworks 2020. After that, all of the components were assembled to form a full
machine. We then started consulting with our project coordinator and supervisor about
the estimation of the budget and the availability of those materials in the local market.
The tools and supplies needed to complete our job were further identified and finalized.
The materials that were recognized as being of appropriate dimensions were later
collected and carefully managed. Following that, the machine was constructed.
The frame was made up of vertical and horizontal steel bars that were held together
using nuts and bolts. After that, the cutting blades which were used to cut the fruit were
attached to a hollow shaft by welding.
10
Two plummer blocks were used to hold the shaft in place so it could rotate properly. The
hollow shaft's outer diameter did not match the inner diameter of the plummer blocks. As
a result, each side of the hollow shaft had a solid shaft with various diameters that fit
precisely into the hollow shaft as well as the plummer. A pulley was attached to the solid
shaft's outer end. The pulley was connected to a motor mounted vertically beneath it. A
V-belt was used to connect the pulley and the motor, and the machine was then operated.
The fabricated product was eventually tested through trials at the university's TTC. Any
flaws discovered during the machine operation were rectified by making minor
adjustments to the design specifications.
Need assessment
Literature review
Material selection
Fabrication
Testing
11
2.5 Governing equation
Belt Length
The length of the belt can be calculated as:
dm π df π (df − dm )2
lb = + + 2lm +
2 2 4lfm [7]
Where,
lb = length of belt
Belt velocity
12
Velocity ratio
The velocity ratio of two pulleys can be calculated as:
N1D1 = N2D2
N D
∴ N1 = D2 [8]
2 1
Motor
Diameter of shaft of motor = 50 mm
Diameter of pulley (1st shaft) = 400 mm
Using above equation,
N1 D2
=
N2 D1
1720 200
or, =
x 100
So, the speed of first shaft (top shaft) will be around 860 rpm
Length of Belt
For calculation of the length of the belt, we have the equation:
D2 + D1 (D2 − D1 )2
L = 2C + π ( )+ [7]
2 4C
Where,
This is the length of the belt from the motor to the first shaft pulley.
Again, the same length pulley will be used from the first shaft pulley to the third shaft
pulley.
For the length of belt of the first shaft (left hand pulley to second shaft pulley), we
have,
D2 + D1 (D2 − D1 )2
L = 2C + π ( )+ [7]
2 4C
L = 1856.63
∴ L ≈ 1856.63 mm
This is the length of belt from first shaft left hand pulley to second shaft pulley.
14
Torque
τ=r ×F
Where,
τ = torque
r = radius of shaft
F = force
For Force,
F =m ×a
F = 0.25 × 9.8 (assuming weight of mango is 0.25kg)
∴ F = 2.45 N
15
2.6 Conceptual Design
16
Figure 12 2Design of mango cutting machine
The above figure is the 2D design of mango cutting machine designed in the solidworks
which is the automatic A.C motor derived machine. It works with the help of
mechanical power of motor. The material used for the project is mild steel, rubber belt,
stainless steel. It consists of three shafts i.e., shaft 1, shaft 2, and shaft 3. In the
combination shaft 1 and shaft 2 are connected in the perpendicular with the help of
different pulley, and bevel gear of different diameter of pulley and 50mm diameter of
17
bevel gear in the same way shaft1 and shaft 3 are also connected parallel by using
different pulley. By doing this, shaft 2 and shaft3 are also in perpendicular with each
other. In this system the pulley and gear plays very important role in the power
transmission of motor to different shaft. All the three shaft consists of blade of
250*100*10 mm dimension exactly situated by maintain the different gaps in the
different shaft. The different gap help to cut the mango of different size in different shaft.
On the top of machine shaft1 and just below that the collector made of strip of gap
50mm are fixed which cut the mango in 50 mm size and the cut mango are collected
the collector of strip gap of 35 mm and again this sized are cut in 35mm size and fall in
the collector of strip gap of 2 mm just below the third shaft and finally the shaft3 cut
the mango size in the 20 mm and collect in the base collector.
If we see the mechanism of cutting the mango, then the collector’s strip gap and the
blade gap are arranged in such a way that the blade exactly passes between the gap of
the two strips of the collector and cuts the mango at the gap size of the blade. And once
when it is cut, its size becomes smaller than the collector’s gap and it falls down into
the other collector, and the same process is repeated again.
The speed of shaft 1 is 250 rpm, while the speeds of the second and third shafts are 125
rpm, allowing the first shaft to cut the mango in a large amount while the second, third,
and slower shafts maintain the required size.
18
2.7 Components of Mango cutting machine
Table 1 Component of mango cutting machine
6 Belt Length
3117.05
Length
1856.63
7 Plummer Diameter 32
19
2.8 Fabrication
After the completion of design and calculation, fabrication was done and before the
fabrication as mentioned before material selection was done and the need material was
observed in our own TTC and available material was taken from there with the
permission TTC director and rest was brought from the market after the market survey.
First of all, the rectangular mild steel bar was cut according to the dimension mention
above in appropriate quantity with the help of cutting grinder and hand cutter and then
all the cut strip was drilled and with the help of nut and bold they all are jointed to form
the frame as shown in the figure below.
After the completion of the frame work, fabrication of the shaft was done for which we
have used hollow shaft and number of blades with above mentioned dimension was
mounted on the shaft by wielding. To hold the shaft and fit it into the plumber block two
secondary solid shaft was inserted into the hollow shaft and was fixed by wielding.
20
Figure 15 Hollow shaft with number of blades
To hold the shaft, the appropriate plumber block having equal dimension of solid shaft
was fixed on the horizontal strip and shaft was inserted on in it. For the power
transmission from the motor to the shaft, pulley was used and fixed on the shaft.
21
For the feeding process, the hopper was fabricated using G.I sheet and was fixed on the top of
the frame by reverting process as shown in the figure above.
Similarly, the other two shaft work with same speed with equal number of blades.
22
CHAPTER 3: GANTT CHART
Month 1 2 3 4 5 6 7 8 9 10 11
1. Literature review
2. Consultation
3. Proposal submission
4. Product design
7. Midterm presentation
8. Fabrication
23
CHAPTER 4: BUDGET ESTIMATION
24
CHAPTER 5: CONCLUSION AND RECOMMENDATION
For the proper analysis of the mango cutting machine, we firstly selected research paper
and analyzed it technically. After that, we designed the model of various parts of the
machine like pulley and belt, cutting blades, plummer blocks, collector, frame, shaft
and computed their physical parameters. We focused on the factors like velocity,
power, and torque through different literature review and data book. This machine will
cut 360 kg mangos in one hour at the speed of 45.5 m/s.For the modelling of the parts,
we used SOLIDWORKS 2020. The 3D model of this machine that we have designed
using Solidworks taking appropriate dimensions from design data book can be used to
fabricate a well-functioning mango cutting machine. Mechanization not only alters the
structure of labor in that sector, but it also has an impact on the nature of the workload.
The mango cutting procedure is divided into three phases. In the first stage, the raw
mangoes are cut into circular slices. The circular slices from the first stage are then
sliced into long rectangular slices in the second stage. The long rectangular slices from
the second stage are then chopped into cubic shapes in the third stage. The cube-shaped
mango pieces can be produced by minimizing the space between the blades and
aligning the blades correctly.
Before manufacturing this machine, we should conduct a thorough market survey to
determine the availability of the components with the dimensions we require. During
the fabrication process, we must be cautious while handling the tools. It's vital to
consider how much time we have available. Any change to a single component of this
machine can have a significant impact on the calculations. Therefore, we should select
the components with the appropriate dimensions first.
25
REFERENCES
26
ANNEX
Ac motor
Frame
27
Hopper (Side View)
28
Pulley
29
Mango cutting machine
30