SCoE, B.E.

(Mechanical) 2015 course, Project stage II, 2021-22

A Project Stage - II Report on

DesignSugarcane
Automatic And Fabrication of Semi-
Bud Cutter Machine
By
Mr. Pratik Deore Exam Seat No B150230861
Mr. Omkar Jadhav Exam Seat No B150230912
Mr. Prathamesh Karde Exam Seat No B150230939
Mr. Abhinandan Kawthe Exam Seat No B150230942

Guide
Prof. Vikram J. Jagtap

Department of Mechanical Engineering

Sinhgad College Of Engineering,
Pune 411041
[2021-22]

SCOE/ Mech/ Projects/UG/21-22/ 82 Date: 29/04/2022

CERTIFICATE

This is to certify that Mr. Pratik Deore (B150230861), Mr. Omkar Jadhav (B150230912), Mr.
Prathamesh Karde (B150230939) and Mr. Abhinandan Kawthe (B150230942), have
successfully completed the project work entitled “Design and Fabrication of Semi-Automatic
Sugarcane Bud Cutter Machine” under my supervision in the partial fulfilment of degree of
Bachelor of Engineering (Mechanical Engineering) of Savitribai Phule Pune University during
academic year 2021-22.
Place:

Date:

Prof. Vikram J. Jagtap Prof. A. P. Pandhare

Guide Head of Department
Mechanical Engineering Department

External Examiner Seal Dr. S. D. Lokhande

Principal
Sinhgad College of Engineering,
Pune, 411041

ACKNOWLEDGEMENT

It is our pleasure to acknowledge a deep sense of gratitude to everyone who has made it

possible for us to complete this project with success. It gives us great pleasure to express

our deep gratitude to our project guide Prof. Vikram J. Jagtap for his support and help

from time to time during the project work.

We would also like to express our gratitude to Prof. A. P. Pandhare, our Head of

Department and Principal Dr. S. D. Lokhande for their support and encouragement in

the project work.

We are also thankful to Prof. V. T. Pawar his valuable and insightful assistance in the

testing phase of the project work.

Finally, yet importantly we would like to thank all staff members and all our colleagues

for their valuable suggestions and support.

 Pratik deore (B150230861)

Omkar Jadhav (B150230912)

Prathamesh Karde (B150230939)

Abhinandan Kawthe (B150230942)

Contents
Pages

COVER PAGE
CERTIFICATION I
ACKNOWLEDGMENT II
CONTENTS III
LIST OF FIGURES IV
LIST OF TABLES V
ABSTRACT VI
Chapter 1 Introduction 1
1.1 Aim 2
1.2 Problem Statement 2
1.3 Objective 2
1.4 Scope 2
1.5 Advantages 2
1.6 Disadvantages 2
Chapter 2 Literature Review 3
Chapter 3 Methodology 8
Chapter 4 Design & Analysis 9
4.1 3D Design 9
4.2 Drafting 12
4.3 Basic Calculation 13
4.4 Analysis 15
 4.5 Components 19
Chapter 5 21
5.1 Manufacturing 21
5.2 Cost Estimation Table 23
5.3 Process Sheet 24
5.4 Safety Precautions 30
5.5 Monthly Magazine 31
Chapter 6 Conclusion 33
References 34

List of Figures
Fig No. Name Page No.

1.1 Traditional Method 1

1.1 Bud chipping Method 1
4.1 Different views of Bud cutter CAD model 11
4.2 Drafting of the whole assembly 12

4.4.1 Geometry of Model 15

4.4.2 Meshing of Geometry 16
4.4.3 Boundary conditions 17
4.4.4 Equivalent tresses 18
4.5.1 Bud Collection Box 19
4.5.2 Blades 19
4.5.3 Pneumatic Actuator 20
4.5.4 Motor 20
5.3.1 Cutting of Materials 24
5.3.2 Welding of Assembly Parts 26
5.3.3 Drilling Operation 27
5.3.4 Finishing of assembly parts 29
 List of Tables
Table No. Name Page No.

4.4.1 Properties of material 15

5.2 Cost estimation table 23
5.5 Monthly Magazine 31

Abstract

Sugarcane is one of the most widely farmed crop over the globe. After harvesting sugarcane,
cutting the sugarcane into chunks is a very time-consuming process. All sugarcane cutting
machines are either manual or semi-automatic. This involves a lot of time and labour for each
machine since the operation is not fully automatic. 

So here we propose a fully automatic sugarcane bud cutter that utilizes pneumatic power for
automatic sugarcane cutting mechanism. The system makes use of a mini tabletop machine with
a powerful motorized arrangement to push an entire sugarcane bud into the machine cutter. Once
a sugarcane stick bud is inserted a rubber gripper roller powered by geared motor is used to drive
the stick towards the cutter at a specific rate. 

A second roller is attached to the system through a screw-based arrangement is used to push the
sugarcane stick towards the other roller and maintain a grip over the cane. The system is further
integrated with a pneumatic cylinder. A cutter blade is attached to the front end of the actuator.
The pneumatic cylinder is powered by an external compressor to drive it back and forth using
high air pressure.  
This blade is used to cut the sugarcane bud into equal pieces in coordination with the feeder
rollers. The machine uses rollers to pull in the sugarcane stick and cutter to cut it. Now the
system also includes a controller circuitry that controls the cutting length of each piece. This
allows the operator to cut the sugarcane in desired pieces. 

CHAPTER 1

• Introduction

The agriculture sector of India has occupied 43% of India’s geographical area, and is
contributing 16.1% of India’s GDP. Agriculture still contributes significantly to India’s GDP
despite decline of its share in India’s GDP. There are number of crops grown by farmers. These
include different food crops, commercial crops, oil seeds etc. Sugarcane is one of the important
commercial crops grown in India. Approximately 80% of the world’s sugar is produced from
sugarcane in tropical and subtropical climates, 70 countries produce sugar from sugarcane, 40
from sugar beet and 10 from both. In agricultural harvesting we require maximum manpower,
ample money and also it is more time-consuming process. In cutting process, we face various
problems, and these are not easily solved. The design of this machine is very simple also easy to
implement. In this manner we are designing the Sugarcane Cutting Machine to reduce effort and
time. In sugar cane farms we are using this machine for cutting purpose. This is user friendly
cutting machine; anyone can handle this machine in any working condition. Skilled persons are
not required for operating this machine.
The need for sugar cane bud chipper is only for the farmers, where they are using a full
size of sugarcanes in the field for the plantation purpose, while using this sugar cane bud chipper,
we can cut it down in to small pieces, compact in size it can also use for plantation. From this we
can save the wastage of remaining portion of the sugar cane.
So here we propose a semi automatic sugarcane bud cutter that utilizes pneumatic
power for semi automatic sugarcane cutting mechanism. The system makes use of a mini
tabletop machine with a powerful motorized arrangement to push an entire sugarcane bud into
the machine cutter.

Fig 1.1 Traditional Method

Fig 1.2 Bud Chipping Method

1.1 Aim:
To design a cost-effective semi-automatic sugarcane bud cutter machine, which will help to cut
the bud of proper size.

1.2 Problem statement:

The old method of cutting node of sugarcane, i.e., by hand is more time consuming.
Remaining sugarcane is used for feeding for animals like cows. Also, the existing (traditional)
tools used for bud cutting of sugar cane are unsafe, messy and need skill and training. The risk of
injury is also too high. This necessitates the development of a node cutting machine for sugar
cane.

1.3 Objectives:
• To reduce the human effort required for sugarcane cutting by developing semi-automated
sugarcane cutting machine.
• To develop machine which have proper control on cutting location.
• To cut maximum number of sugarcanes at minimum time so efficiency will be increased.
• To develop machine which is economical.

• Scope
This project work has provided us an excellent opportunity and experience, to use our limited
knowledge. We gained a lot of practical knowledge regarding, planning, purchasing, computing
and machining while doing this project work.

1.5 Advantages
 • Save large amount of sugarcane bud from waste by plant in farm.
• Initial cost of machine is very easy to handle for unskilled persons for e.g. Farmers and
labours related with farm.
• Saved sugarcane bud used for fodder for animals.
• Other costly energy is not required
• Sugarcane bud cutting operation is very fast as compared to traditional system of
sugarcane planting.
• Seed cost can be reduced up to 85%
• Disadvantages
• Requires Air Supply
• Blade needs to be replaced/sharpened from time to time.

CHAPTER 2
Literature Review

“Sugarcane Cutting Machine” By Vahid Jamadar, Arbaz Sawar, Hemant Pol, Niraj
Deshpande, Sandip Sawant, Vishnu Patil.
 This research paper helps to design and fabricate small scale sugarcane cutting machine
for sugarcane harvesting to reduce farmer’s effort and to increase production of agricultural
goods. Compared to manual harvesting this machine has a capacity to cut canes in faster rate. It
is economical. This paper helps in laying design foundation for any aspiring user to fabricate a
machine for application in their farms. It helps improve economic growth of the nation. In
cutting process, we face various problems and these are not easily solved. The design of this
machine is very simple also easy to implement. In this manner we are designing the Sugarcane
Cutting Machine to reduce effort and time. In sugar cane farms we are using this machine for
cutting purpose. This is user friendly cutting machine, anyone can handle this machine in any
working condition. Skilled persons aren’t required for operating this machine
Comparing with manual harvesting half of harvesting time and need of labours are
reduced. The cost of harvesting is reduced by many folds when compare to manual harvesting.
Automation has very huge scope in both cultivation and harvesting of such agricultural
application. Sugarcane is tall grass with thick stalk and is cut manually by steel blades and
transported to nearly sugar factories. The present sugarcane harvesters are big in size and of huge
cutting capacity. Due to their size, it is next to impossible to use these automatic harvesters in the
small farm. It is also not very economically viable to the poor segment of the country like here in
India. In this paper an attempt is made to design and manufacture a small semiautomatic
sugarcane cutter by fabricating it locally and hence prove using this design people may fabricate
their very own semi-automatic cutters at their locale. The design is very simple and can be
fabricated with local fabricators.

“Sugarcane Bud Chipper with Multi Cutter using Slider Crank Mechanism” by N. Dileepan,
G. Sivakumar, V. Sathishkumar, M. Siranjeevi, J. Thulasirajan.

This paper helps to design and fabricate small scale sugarcane cutting machine for
sugarcane harvesting to reduce farmer’s effort and to increase production of agricultural goods.
Compared to manual harvesting this machine has a capacity to cut canes in faster rate. It is
economical. This project helps in laying design foundation for any aspiring user to fabricate a
machine for application in their farms. It helps improve economic growth of the nation. In
manual harvesting to cut one acre of sugarcane 15-16 labors are required they take 3 days to cut
one acre. By using this machine problem of the labour crises can be reduced. Comparing with
manual harvesting only 18% of labors are required, it makes the process faster hence reduces
most of the harvesting time and labor required to operate the machine is also less. This machine
is helpful for both small and big farmers. To overcome these problems this project work aims to
develop low cost sugarcane harvesting machine which is more efficient and having simple
mechanism for cutting the sugarcane at a faster rate. The purpose of developing this machine is
to reduce cost and time required for sugarcane harvesting. Sugarcane harvesting machine which
is economical, more efficient and cuts the sugarcane at faster rate and it will be helpful for small
scale farmers, unskilled labors can also operate without difficulty. By using this harvesting
machine, we can also solve the problem of labor shortage.
The need for sugar cane bud chipper is only for the farmers, where they are using a full
size of sugarcanes in the field for the plantation purpose, while using this sugar cane bud chipper,
we can cut it down in to small pieces, compact in size it can also use for plantation from this we
save the wastage of remaining portion of the sugar cane.
The sugarcane machine is very useful to small scale farmer to planting sugarcane bud .and also
time is saved by this process as compared to the traditional system of sugarcane bud plant. Extra
sugarcane waste in small form that can be saved by using sugar cane bud cutting machine that
can be used as a white sugar production and juice. Also, the wood cutter is very useful for the
farmers, and it reduces the human

“Design and fabrication of sugarcane node cutting machine” by Siddhesh Phapale, Prof.
A.A.Tamboli, Prof. D.L.Shinde.

 To produce maximum sugarcane yield, traditional method is not suitable as sugarcane
planting with traditional methods is costly, time-consuming and necessary compression of buds
in the field is not achieved easily because of stalk planting in sugarcane. In tradition planting
method, great human force and high volume of sugarcane stalk in hectare is required. To solve
this problem and mechanizing of sugarcane planting, we suggest the application of machine
vision system and Image Processing methods to identify nodes from sugarcane and to plant it as
a seed by planting machines.
 Sometimes, cut may appear on the bud as well, which results into no germination of the
bud and we lose the seed. In addition to proper controlled cutting of stalk, it is necessary to
identify any disease in the node as it affects the yield and quality of the sugarcane. Unfortunately,
the traditional sugarcane planting machines do not have any such facility. This project deals with
solutions to overcome these problems and talks about use of image processing method for seed
selection.
  The number of applications using machine vision and digital image processing
techniques in the agricultural sector is increasing rapidly. These applications include land/aerial
remote sensing of crops, detection and recognition of pathological stress conditions, shape and
colour characterization of fruits, among many other topics. In fact, quantification of the visual
properties of horticultural products and plants can play an important role to improve and
automate agricultural management tasks.

“Design and Fabrication of Sugarcane Cutting Machine for Cane-Can Industry” by

Nagpur Mohammad Zeeshan Ali K. I. Ahmad

The sugar cane harvesting is a very critical activity which involves great effort or work by
labor for cutting the cane. The labors are experience sustained injuries due to intense stress on
the joints and muscles of the body. And also, modern world needs faster rate of production of
agriculture products. This research paper is based on design and fabrication of sugarcane cutting
machine for Cane-can industry, this machine will be required to cut the sugar cane of size upto
10 ft. to a size of approx.2ft sugarcane stick should be cut in one cycle.
The need of this project is limited to developing a sugar cane cutting machine for Cane-Can
industry, Nagpur. Multiple sugarcane stick should be cut in one cycle. The machine has to be
semi-automatic; the operator will be responsible for feeding the machine with sugarcane sticks.
The pieces of sugarcane will be finally collected by the operator at the end of operation. This
project is a result of agriculture industry need, by developing a semi-automatic sugarcane cutting
machine to reduce labor cost as compared to manual operation. Also, consumed less time as
compared to manual system and it will be safe.
With successful completion of the project, the company Cane-can industry will be directly
benefited, Design and fabrication of sugarcane cutting machine will reduce labor time of
manually cutting the sugarcane, ensure safety of workers working on sugarcane cutting, reduce
the cost of labour involved in the cutting operation and it can cut multiple sugarcane stick in one
operation.

“Design & Fabrication of Semiautomatic Sugarcane Bud Chip Cutting Machine” by   R.

Amudhan R. Mani K. Karthikayan D. Mathan L. Arunkumar

Sugarcane Bud Chipping Machine, which is used for producing Sugarcane Bud for the plantation
and growing sugarcane which is helpful to farmer that reduces the initial cost, and increase the
yield of production in sugarcane. One alternative to reduce the mass and improve the quality of
seed cane would be to plant excised auxiliary buds of cane stalk, popularly known as bud chips.
These bud chips are less bulky, easily transportable and more economical seed material. The bud
chip technology holds great promise in rapid multiplication of new cane varieties. The sugar
industry is a focal point for socio-economic development in rural areas, mobilizing- rural
resources, generating employment and higher incomes, and supporting the development of
transport and communication facilities.
 This paper gives a detailed explanation of the various processes taking place in a complete
semiautomatic sugar cane bud chip cutting machine.
“Cam operated sugarcane bud cutting machine” by Rushikesh S. Patil, Dnyaneshwar B.
Patil, Dushyant M. Patil, Shashikant B. Khandagale

The existing (traditional) tools used for bud chipping of sugar cane are unsafe, messy and
need skill and training. The risk of injury is also too high. This necessitates the development of a
bud chipping machine for sugar cane. In this direction, literature survey, patent search, market
survey and concept generation were carried out. Different concepts were developed using
concept generation. In this paper author has explained about designing the sugarcane bud cutting
machine which reduces the wastage of sugarcane and also reduces the transportation cost. The
production of bud using this automatic sugarcane bud cutting machine is high as compared to
other conventional machines available in the market.This is a new concept applied for sugarcane
bud cutting process which finds suitable and viable and reduces human effort compared to
traditional methods. This machine provides comfort to work for different positions depending
upon ergonomics. The time requirement as well as efficiency of machine depends upon the size
of sugarcane. The sugarcane bud cutting machine is very useful for small scale farmers for
planting sugarcane buds, also time is saved by this process as compared to traditional system of
sugarcane bud cutting. Extra piece of sugarcane bud waste in small scale farm which can be
saved by using sugarcane bud cutting machine that can be used as fodder for animals.
CHAPTER 3  

Methodology

PHASE I
-We started our work with literature survey.
-Search many research papers from various articles and published journal papers.
- Then we collected all the topic related data from these research papers and studied them in  
detailed manner along with the standard reference books and academic books.
-Reference sites:
• http://explore.ijert.org/
• http://www.ijetcse.com/
• http://industrialscience.org/
• http://www.ijist.net/

-Worked on diff. Mechanisms that can be useful for our project.

-We have done a rough 3D model in Catia.
- After the final analysis and material selection we go out in the market to purchase the required
components with required specifications.
- In this purchasing process we approximately estimated the cost required to purchase the
components and for machining.
-We selected standard components.
- Finally, our product will be manufactured in second semester and results and testing will be
carried out.

PHASE II
Actual preparation of project:
-We will complete calculations of remaining parts.
-We will purchase standard components from market.
-We will be done a rough 3D model of our project.
- Manufacturing will be done.
-Assembly will be done.
-Testing of set up will be done.
-Representation actual project
CHAPTER 4
Design And Analysis

4.1 3D-Design

Computer-aided design (CAD) is the use of computers to aid in the creation, modification,

analysis, or optimization of a design. CAD software is used to increase the productivity of the
designer, improve the quality of design, improve communications through documentation, and to
create a database for manufacturing. CAD output is often in the form of electronic files for print,
machining, or other manufacturing operations. 
CAD is used as follows:

• To produce detailed engineering designs through 3-D and 2-D drawings of the physical
components of manufactured products.
• To create conceptual design, product layout, strength and dynamic analysis of assembly
and the manufacturing processes themselves.
• To prepare environmental impact reports, in which computer-aided designs are used in
photographs to produce a rendering of the appearance when the new structures are built.

CAD systems exist today for all of the major computer platforms, including Windows,
Linux, Unix and Mac OS X. The user interface generally centers around a computer mouse, but a
pen and digitizing graphic tablet can also be used. View manipulation can be accomplished with
a space mouse (or space ball). Some systems allow stereoscopic glasses for viewing 3-D models.
In our olden days, engineers, designers and draughts men were struggling to produce and
submit engineering drawings in their scheduled times. It was mainly due to tremendous efforts
they had taken to produce both new drawings and edited/updated drawings. Every line, shapes,
measurements, scaling of the drawings - all made them headache to the design / drafting field.
All these difficulties and pressures over-ridden by Computer Aided Design Drafting (CAD
Drafting) technology.
The advantages of CAD include: the ability to producing very accurate designs; drawings
can be created in 2D or 3D and rotated; other computer programs can be linked to the design
software. With manual drafting, you must determine the scale of a view before you start drawing.
This scale compares the size of the actual object to the size of the model drawn on paper. With
CAD, you first decide what units of measurement you will use, and then draw your model at 1:1
scale, should one of the main benefits of CAD. When you draft manually, you first select a sheet,
which usually includes a pre-printed border and title block. Then you determine the location for
views' plans, elevations, sections, and details. Finally, you start to draw. With CAD, you first
draw your design, or model, in a working environment called model space. You can then create a
layout for that model in an environment called paper space.
A layout represents a drawing sheet. It typically contains a border, title block,
dimensions, general notes, and one or more views of the model displayed in layout viewports.
Layout viewports are areas, similar to picture frames or windows, through which you can see
your model. You scale the views in viewports by zooming in or out. Manual drafting requires
meticulous accuracy in drawing line-types, line-weights, text, dimensions, and more. Standards
must be established in the beginning and applied consistently. With CAD, you can ensure
conformity to industry or company standards by creating styles that you can apply consistently.
You can create styles for text, dimensions, and line-types.
With manual drafting, you use drawing tools that include pencils, scales, compasses,
parallel rules, templates, and erasers. Repetitive drawing and editing tasks must be done
manually in CAD, you can choose from a variety of drawing tools that create lines, circles,
spline curves, and more. You can easily move, copy, offset, rotate, and mirror objects. You can
also copy objects between open drawings. With manual drafting, you must draw objects carefully
to ensure correct size and alignment. Objects drawn to scale must be manually verified and
dimensioned. With CAD, you can use several methods to obtain exact dimensions. The simplest
method is to locate points by snapping to an interval on a rectangular grid. Another method is to
specify exact coordinates. Coordinates specify a drawing location by indicating a point along an
X and Y axis or a distance and angle from another point. With object snaps, you can snap to
locations on existing objects, such as an endpoint of an arc, the midpoint of a line, or the center
point of a circle. With polar tracking, you can snap to previously set angles and specify distances
along those angles. Revisions are a part of any drawing project. Whether you work on paper or
with CAD, you will need to modify your drawing in some way. On paper, you must erase and
redraw to make revisions to your drawing manually. CAD eliminates tedious manual editing by
providing a variety of editing tools. If you need to copy all or part of an object, you don’t have to
redraw it. If you need to remove an object, you can erase it with a few clicks of the mouse. And
if you make an error, you can quickly undo your actions. Once you draw an object, you never
need to redraw it. 
To work efficiently using the cad the organisation must focus on the following areas where it
needs to be on upper side. 

• Most popular CAD software like AutoCAD, ProgeCAD, Micro HYPERLINK

"https://www.bentley.com/"S HYPERLINK "https://www.bentley.com/"tation are high
priced for individuals. Alternatively, individuals can try free opensource CAD drafting
 software QCAD, LibreCAD and OpenSCAD.
• Every new release of the CAD software, operator has to update their skills.
•
Improper use of blocks and layers
make updating and modification of the drawings a cumbersome task for another person. 

Fig 4.1 Different views of Bud cutter CAD model

4.2 Drafting:

Fig. 4.2 Drafting of the whole assembly.

 
 
4.3 Basic calculation

Pneumatic Cylinder:
Given data:
Selecting Cylinder: 25 
• Area of piston 
= π/4*25^2 
= 490.873 mm^2

• Volume of cylinder = stroke *area of piston

= 25*π/4*25^2
= 49087.385 m^3

• Outstroke force (F) = pressure *Area of cylinder

= 0.4*490.873
= 196.349 N   

• Piston rod area A1 

= π/4*d^2
= π/4*8^2
= 50.20 mm^2

Effective area = piston area- piston rod area

                         = 490.873 -50.20
                         = 440.673 mm^2
In-stroke force = P*A
                          = 0.4*440.673
                         =176.2692 N 
Motor calculation:
Total mass of the Sugarcane=2kg.
Total force is calculated by,
F = m*a
  = (2*9.81)
  =20 N
So, on each wheel load is equals to (20/2) = 10N
We are using One inch diameter (25.4mm) wheels hence the total required torque is calculated
as,
T = F*R
  = (10 * 0.0127)
  = 0.127 N-m-------- A
Means 0.127 Watt

For 12V and 5A DC battery motor,

P = V*I
  = (12*5)
  = 60 Watt.

4.4 Analysis:

4.4.1 Geometry:
The material selected for designing is structural steel. Density is 7850 kg/m^3.
Young’s modulus value for the material is 2E +11 Pa. Poisson’s Ratio for the material is 0.3.
Bulk modulus is 1.6667E+11. Shear Modulus for the material is 7.6923E +10.
 Fig. 4.4.1 Geometry of CAD Design

Table. 4.4.1 Properties of material.

4.4.2 Meshing:
For meshing no of nodes selected was 16801. Total elements are 13398.

Fig. 4.4.2 Converting Geometry into Meshing.

4.4.3 Boundary Condition:

Fig. 4.4.3[a] Boundary Conditions.

 Fig. 4.4.3[b] Boundary Condition on wheel.

4.4.4 RESULT- Equivalent Stresses and Total Deformation:

After analysis the minimum equivalent stress was found out to be 3.1046e-013 MPa. And
maximum stress is 0.11817 MPa. Average stress is 8.2963e-004.

Fig. 4.4.4[a] Equivalent Stresses on machine.

Fig. 4.4.4[b] Total deformation on assembly.

4.5 Components:

• Bud Collection Box 

  

Fig 4.5.1 Bud Collection Box

 Bud collection box is used to collect buds which are cut by cutter at supporting plate. So that
proper collection of buds can be done. Because of this, all buds are collected at a one place

• Cutter Blade

Fig 4.5.2 Blades

This is the main section of the scooping machine. The scoop cutter is used to cut the
sugarcane bud and to get the same size of sugarcane bud. Because of cutter the wastage of
sugarcane reduces and safety of farmer increases.

• Pneumatic Actuator

Fig 4.5.3 Pneumatic Actuator

Pneumatic actuators are mechanical devices that use compressed air acting on a piston inside a
cylinder to move a load along a linear path. Unlike their hydraulic alternatives, the operating
fluid in a pneumatic actuator is simply air, so leakage doesn’t drip and contaminate surrounding
areas. The basic pneumatic cylinder consists of a cylindrical chamber with a movable piston and
intake and exhaust channels. When compressed air or other gas is pumped into the bottom of the
cylinder, the gas expands, pushing the movable piston upwards and generating force. Pneumatic
cylinders, also known as air cylinders, have advantages over hydraulics in some cases and are
used in a wide variety of applications.
 
4. Motor:

Fig 4.5.4 Motor

An electric motor is an electrical machine that converts electrical energy into mechanical energy.
Most electric motors operate 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. 
CHAPTER 5

5.1 MANUFATURING

5.1.1 Cost Estimation:

Cost estimation may be defined as the process of forecasting the expenses that must be
incurred to manufacture a product. These expenses take into a consideration all expenditure
involved in a design and manufacturing with all related services facilities such as pattern
making, tool, making as well as a portion of the general administrative and selling costs.

5.1.2 Purpose of Cost Estimation:

• To determine the selling price of a product for a quotation or contract so as to ensure a
reasonable profit to the company.
• Check the quotation supplied by vendors.
• Determine the most economical process or material to manufacture the product.
• To determine standards of production performance that may be used to control the cost.

5.1.3 Type of Cost Estimation:

• Material cost
• Machining cost

1] Material Cost Estimation

Material cost estimation gives the total amount required to collect the raw material
which has to be processed or fabricated to desired size and functioning of the components.

These materials are divided into two categories.

• Material for fabrication:
In this the material in obtained in raw condition and is manufactured or processed to
finished size for proper functioning of the component.

• Standard purchased parts:

This includes the parts which was readily available in the market like Allen screws etc. A
list is forecast by the estimation stating the quality, size and standard parts, the weight of
raw material and cost per kg. For the fabricated parts.
2] Machining Cost Estimation

This cost estimation is an attempt to forecast the total expenses that may include
manufacturing apart from material cost. Cost estimation of manufactured parts can be
considered as judgment on and after careful consideration which includes labour, material and
factory services required to produce the required part.

5.1.4 Procedure for Calculation of Material Cost:

The general procedure for calculation of material cost estimation is after designing a project,
• A bill of material is prepared which is divided into two categories.
• Fabricated components
• Standard purchased components
• The rates of all standard items are taken and added up.
Cost of raw material purchased taken and added up.

S/N Particulars Specification Rate Unit Total

(Per Unit)
1. Pneumatic Double Acting 2500 1 2000
Cylinder Cylinder
2. Frame MS 3500 1 3000

3. Battery 12 volt & 5 A 1500 1 1500

4. Motor 1800 1 1800

5 Roller 150 2 300

Bearing
6 Hand lever 5/2 700 1 700
valve
7 Nuts, bolt, 500 500
etc.
Total 9800
Cost
Manufacturing Cost 2200
Material Cost 9800
Total Cost Rs.12000
5.2 Cost Estimation Table

Table-5.2 Cost Estimation Table

5.3 PROCESS SHEET:

Following operations were while fabricating the project

5.3.1 Cutting: -

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

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

The material as our required size. The machine used for this operation is power chop saw. A
power chop saw, also known as a drop saw, is a power tool used to make a quick,
accurate crosscut in a work piece at a selected angle. Common uses include framing operations
and the cutting of moulding. Most chop saws are relatively small and portable, with common
blade sizes ranging from eight to twelve inches.

Fig. 5.3.1 Cutting of material.

The chop saw makes cuts by pulling a spinning circular saw blade down onto a work piece in a
short, controlled motion. The work piece is typically held against a fence, which provides a
precise cutting angle between the plane of the blade and the plane of the longest work piece
edge. In standard position, this angle is fixed at 90°. A primary distinguishing feature of the mitre
saw is the mitre index that allows the angle of the blade to be changed relative to the fence.
While most mitre saws enable precise one-degree incremental changes to the mitre index, many
also provide "stops" that allow the miter index to be quickly set to common angles (such as 15°,
22.5°, 30°, and 45°). The time required for this operation is 50 minutes.

5.3.2 Welding: -
Welding is a fabrication or sculptural process that joins materials, usually metals or
thermoplastics, by using high heat to melt the parts together and allowing them to cool causing
fusion. Welding is distinct from lower temperature metal-joining techniques such as brazing and
soldering, which do not melt the base metal.

In addition to melting the base metal, a filler material is typically added to the joint to form a
pool of molten material (the weld pool) that cools to form a joint that, based on weld
configuration (butt, full penetration, fillet, etc.), can be stronger than the base material (parent
metal). Pressure may also be used in conjunction with heat, or by itself, to produce a weld.
Welding also requires a form of shield to protect the filler metals or melted metals from being
contaminated or oxidized.
Square pipes of different lengths to make frame. The machine used for this operation is electric
arc welding. Electrical arc welding is the procedure used to join two metal parts, taking
advantage of the heat developed by the electric arc that forms between an electrode (metal filler)
and the material to be welded. The welding arc may be powered by an alternating current
generator machine (welder). This welding machine is basically a single-phase static transformer
Suitable for melting RUTILE (sliding) acid electrodes. Alkaline electrodes may also be melted
by alternating current if the secondary open-circuit voltage is greater than 70 V.
Many different energy sources can be used for welding, including a gas flame (chemical), an
electric arc (electrical), a laser, an electron beam, friction, and ultrasound. While often an
industrial process, welding may be performed in many different environments, including in open
air, under water, and in outer space. Welding is a hazardous undertaking and precautions are
required to avoid burns, electric shock, vision damage, inhalation of poisonous gases and fumes,
and exposure to intense ultraviolet radiation.

Fig. 5.3.2 Welding of Assembly Part.

The welding current is continuously regulated (magnetic dispersion) by turning the hand wheel
on the outside of the machine, which makes it possible to select the current value, indicated on a
special graded scale, with the utmost precision. To prevent the service capacities from being
exceeded, all of our machines are fitted with an automatic overload protection which cuts of the
power supply (intermittent use) in the event of an overload. The operator must then wait for a
few minutes before returning to work. This welding machine must be used only for the purpose
described in this manual. Read the entire contents of this manual before installing, using or
servicing the equipment, paying special attention to the chapter on safety precautions. Contact
your distributor if you do not fully understand these instructions. The time required for this
operation is 120 minutes.

5.3.3 Drilling: -

Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in solid
materials. The drill bit is usually a rotary cutting tool, often multi-point. The bit is pressed
against the work-piece and rotated at rates from hundreds to thousands of revolutions per
minute. This forces the cutting edge against the workpiece, cutting off chips (swarf) from the
hole as it is drilled.
In rock drilling, the hole is usually not made through a circular cutting motion, though the bit is
usually rotated. Instead, the hole is usually made by hammering a drill bit into the hole with
quickly repeated short movements. The hammering action can be performed from outside the
hole (top-hammer drill) or within the hole (down-the-hole drill, DTH). Drills used for horizontal
drilling are called drifter drills.

In rare cases, specially-shaped bits are used to cut holes of non-circular cross-section; a square
cross-section is possible.

Fig. 5.3.3 Drilling Operation.

Drilled holes are characterized by their sharp edge on the entrance side and the presence of burrs
on the exit side (unless they have been removed). Also, the inside of the hole usually has helical
feed marks.

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

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

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

Finishing is a broad range of industrial processes that alter the surface of a manufactured item to
achieve a certain property. Finishing processes may be employed to: improve appearance,
adhesion or wettability, solder ability, corrosion resistance, tarnish resistance, chemical
resistance, wear resistance, hardness, modify electrical conductivity, remove burrs and other
surface flaws, and control the surface friction. In limited cases some of these techniques can be
used to restore original dimensions to salvage or repair an item.
An unfinished surface is often called mill finish. The edges with grinder using grinding wheel.
The machine used for this operation is hand grinder. An angle grinder, also known as a side
grinder or disc grinder, is a handheld power tool used for cutting, grinding and polishing. Angle
grinders can be powered by an electric motor, petrol engine or compressed air.

The motor drives a geared head at a right-angle on which is mounted an abrasive disc or a

thinner cut-off disc, either of which can be replaced when worn. Angle grinders typically have
an adjustable guard and a side-handle for two-handed operation. Certain angle grinders,
depending on their speed range, can be used as sanders, employing a sanding disc with a
backing pad or disc. The backing system is typically made of hard plastic, phenolic resin, or
medium-hard rubber depending on the amount of flexibility desired. The time required for this
operation is 20 minutes.

Fig. 5.3.4 Finishing of Assembly Part.

5.4 SAFETY PRECAUTIONS:
The following points should be considered for the safe operation of machine

And to avoid accidents: -

• Use Tools and Machines Properly.
• Wear Protective Equipment.
• Follow Correct Procedures, Don’t Take Shortcuts.
• All the parts of the machine should be checked to be in perfect alignment.
• All the nuts and bolts should be perfectly tightened.
• The operating switch should be located at convenient distance from the operator so as to
control the machine easily.
• The inspection and maintenance of the machine should be done from time to time.
• All the nuts and bolts should be perfectly tightened.
• Keep the Machine away from water
The inspection and maintenance of the machine should be done from time to time.
5.5 MONTHLY FLOW OF PROJECT:

Sr. July Jan

Activity/month Aug Sept Oct Nov Dec Feb March
No 21 22

1 Search of topic

Selection of
2 topic and
research papers

Finalizing of
3
project

Literature
4
review
Basic diagram
5 and study of
components
Cad diagram
and starting the
6
calculation of
components

7 Calculations

Finalizing the
calculations and
preparing the
8
final cad
diagram with
dimensions
Starting
9
manufacturing
10 Buying the
standard
components
 from market
Testing of
11
model
Rough draft of
12
report
13 Final report
Table. 5.5 Monthly Magazine.

RESULT:
Fig. 2 shows the Bud size by using Traditional method it’s of Irregular size
and quite a long in size. While fig. 3 shows bud size by using this machine, which
is quite perfect and good for use.

CHAPTER 6
Conclusion:
In rural areas people faced issues like wastage of sugarcane, human effort required, fatigue to
operator. All these problems are being eliminated and this machine can be successfully
implemented for the increase in the production rate of the bud, time required for cutting each bud
will be reduced. Also, sugarcane wastage is reduced because of proper installation of clamping to
hold the Sugarcane. By providing high profits at low investment and also by simplifying bud
removal process along with minimizing labor requirement, our machine proves to be highly
profitable investment for farmers and breakthrough in farming technology.

REFERENCES

• “Sugarcane Cutting Machine” By Vahid Jamadar, Arbaz Sawar, Hemant Pol, Niraj
Deshpande, Sandip Sawant, Vishnu Patil.

• “Sugarcane Bud Chipper with Multi Cutter using Slider Crank Mechanism” by N.
Dileepan, G. Sivakumar, V. Sathishkumar, M. Siranjeevi, J. Thulasirajan. 

• “Design and fabrication of sugarcane node cutting machine” by Siddhesh Phapale, Prof.
A.A.Tamboli, Prof. D.L.Shinde.
• “Design and Fabrication of Sugarcane Cutting Machine for Cane-Can Industry” by
Nagpur Mohammad Zeeshan Ali K. I. Ahmad

• “Design & Fabrication of Semiautomatic Sugarcane Bud Chip Cutting Machine” by   R.

Amudhan R. Mani K. Karthikayan D. Mathan L. Arunkumar

• “Cam operated sugarcane bud cutting machine” by Rushikesh S. Patil, Dnyaneshwar B.

Patil, Dushyant M. Patil, Shashikant B. Khandagale