MEKELLE UNIVERSITY

EIT-M
SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

Thesis Title: Design of stone remover machine from farm land

A thesis submitted in partial fulfillment of the requirement for the award of

BSc Degree in Mechanical Engineering

Prepared by

No. Name ID Number

1 Adisalem Gebrehiwot EITM/UR81743/07

2 Fisseha Birhane EITM/UR82256/07

3 Tesfay Gebru EITM/UR83260/07

Advisor: Melaku D. (MSc.)

June 2019

Mekelle, Ethiopia
 DECLARATION
We hereby declare that the work which is being presented in this thesis, entitled as design of
stone remover machine from farm land with SOLID WORKS 2016 and some formulas are
originally work of our own. It has not been presented for a degree program of any other university
and all the materials used for this thesis have been duly acknowledged and we approve this by our
signature.

1. Adisalem Gebrehiwot
_________________________ ________________________

Signature Date

2. Fisha Birhane
________________________ _________________________

Signature Date

3. Tesfay Gebru
________________________ _________________________

Signature Date

This is to certify that the above declaration made is correct to the best of our knowledge.

Ins. Melaku D. (Advisor)

_______________________ _________________________

Signature Date

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 Acknowledgment
First of all, we would like to thanks God that have given us the opportunity to complete this study.
His willingness has made it possible for us as the author to complete the thesis in time.
Next, we would like to take this opportunity to give our special thanks to our dedicated advisor
Ins. Melaku Desalegn (MSc) who gives us unlimited guidance, instructions, and encouragement
at every step of our thesis, and who give us necessary suggestions and comments. We appreciate
his support with his knowledge and patience. Then we would like to say thanks for all our friends
where they help us directly or indirectly. We very indebted to all individual our friends and others
for their supports to the success of this thesis.so we would like to thank them again sincerely.

Also, we want to thank Mekelle University, especially school of Mechanical and industrial
engineering for teaching us and for creating different learning opportunities.

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 Abstract
This paper discusses on the design of stone remover machine from farmland that is proposed to
improve the productivity and working environment of farmlands.

In a many Farm fields, stones are present in the soil. Stones are a major problem in a farm to
resist the growth of plants; as the result the amount of productivity of crops is reduced. It is also
damage the cultivating tools and harvesting materials. Most of farmers collect stones manually.
In a process of removing stone, operation involves digging up the stones and separating it from
the soil. But manual removal of stones fails to dig out all the stones from the field and many
stones still remain in the ground after collecting stones from the field. Hence, it has planned to
design a stone remover machine and to study its performance. Major components of the
developed machine are digging blade, conveying unit, stone collecting trolley, hydraulic system
of dumping and power transmission system. A frame holds the different components of machine.
Power take off (PTO) shaft operated conveyor was attached at the upper edge of digging blade,
which is operated at required speed by attaching at the back of tractor. The problem statement,
objectives, methodology, concept screening and concept scoring through PDD technique,
literature reviews, design analysis including preliminary design, geometric analysis, and
component analysis, manufacturing process, results and discussions are available. The last
clarification discusses about the conclusions and recommendation followed by reference and
appendices.

Key words: Remove, conveying unit, digging, PTO, transmission system

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Table of Contents page no
DECLARATION ............................................................................................................................. i
Acknowledgment ............................................................................................................................ ii
Abstract .......................................................................................................................................... iii
List of figures ................................................................................................................................. vi
List of tables .................................................................................................................................. vii
List of symbols ............................................................................................................................. viii
CHAPTER ONE ............................................................................................................................. 1
INTRODUCTION .......................................................................................................................... 1
1.1. Introduction about stone remover machine from farm land ............................................. 1
1.2. Background of the study .................................................................................................. 2
1.3. Statement of problem and justification ................................................................................ 3
1.4. Objectives ............................................................................................................................ 3
1.4.1. General objective .......................................................................................................... 3
1.4.2. Specific objectives ........................................................................................................ 3
1.5. Significance of the study...................................................................................................... 4
1.6. Scope of the study ................................................................................................................ 4
1.7. Limitations of the study ....................................................................................................... 4
1.8. Organization of the study ..................................................................................................... 4
CHAPTER TWO ............................................................................................................................ 5
LITRATURE REVIEW .................................................................................................................. 5
2.1 Agricultural equipment ......................................................................................................... 5
2.3. Classifications of stone remover machines .......................................................................... 6
CHAPTER THREE ...................................................................................................................... 11
METHODOLOGY ....................................................................................................................... 11
3.1. Data collection methodology ............................................................................................. 11
3.2. Concept generation and selection method ......................................................................... 11
3.3. Material Selection methods and materials used: ................................................................ 11
3.4. Design analyzing methodology.......................................................................................... 12
CHAPTER FOUR ......................................................................................................................... 13
DESIGN ANALYSIS ................................................................................................................... 13
4.1. Preliminary design analysis ........................................................................................... 13

iv
 4.1.1. Concept generation ..................................................................................................... 13
4.1.2. Concept screening and selection ................................................................................. 16
4.1.3. Concept scoring .......................................................................................................... 17
4.2. Geometry and mechanism of the remover ......................................................................... 18
4.3. Detail Parts Design Analysis ............................................................................................. 19
4.3.1. Design of digging blade .............................................................................................. 21
4.3.2. Design of chain conveyor system ............................................................................... 24
4.3.3. Design of conveyor Shaft............................................................................................ 33
4.3.4. Design of Universal (Hooke’s) Coupling ................................................................... 35
4.3.5. Design of belt drive ..................................................................................................... 36
4.3.6. Design of flat belt pulley............................................................................................. 40
4.3.7. Design of key .............................................................................................................. 41
4.3.8. Design of bevel Gears ................................................................................................. 42
4.3.10. Design of stone collector .......................................................................................... 51
4.3.11. Design of hydraulic system of dumping ................................................................... 54
4.3.12. Design of Bolt and Nut ............................................................................................. 57
4.3.13. Design of frame......................................................................................................... 60
4.4. Selected elements of the machine ...................................................................................... 61
4.4.1. Selection of bearings ................................................................................................... 61
4.4.2. Rubber wheels ............................................................................................................. 62
4.4.3. Hydraulic Fluid and lines ............................................................................................ 62
CHAPTER FIVE .......................................................................................................................... 63
RESULTS AND DISCUSSION ................................................................................................... 63
Manufacturing processes of stone remover machine from farmland........................................ 64
Parts assembly procedures ........................................................................................................ 65
CHAPTER SIX ............................................................................................................................. 66
CONCLUSION AND RECOMMENDATION ............................................................................ 66
6.1. Conclusion ......................................................................................................................... 66
6.2. Recommendation ............................................................................................................... 67
References ..................................................................................................................................... 68
Appendices .................................................................................................................................... 69

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 List of figures
Figure 1:- Farmlands with stones .................................................................................................... 3
Figure 2:- mechanical operated stone remover ............................................................................... 7
Figure 3:- hydraulically operated stone removers .......................................................................... 7
Figure 4:- hydraulically dumping stone removers .......................................................................... 8
Figure 5:- advanced bucket conveyor stone remover ..................................................................... 9
Figure 6:- slat conveyor type stone remover................................................................................... 9
Figure 7:- bucket conveyor ........................................................................................................... 10
Figure 8:- back side (left) and front end (right) stone removers ................................................... 13
Figure 9:- rotary blade operated digging stone ............................................................................. 14
Figure 10:- chain conveyor mechanism stone remover ................................................................ 15
Figure 11:- three linkage mechanism of stone removing.............................................................. 15
Figure 12:- Free hand sketching of stone remover machine ......................................................... 18
Figure 13:- Free body diagram and distribution of forces of digging blade ................................. 21
Figure 14:- deformed shape of digging blade via ANSYS ........................................................... 23
Figure 15:- counter plot of deformation for digging blade ........................................................... 23
Figure 16:- digging blade resolved forces free body diagram ...................................................... 26
Figure 17:- Chain drive ................................................................................................................. 30
Figure 18:- Tooth profile of sprocket............................................................................................ 32
Figure 19:- Rim profile of sprocket .............................................................................................. 32
Figure 20:- Universal or hook coupling ........................................................................................ 35
Figure 21:- Open belt drive. .......................................................................................................... 37
Figure 22:- representations in open belt drive .............................................................................. 38
Figure 23:- Terms used in bevel gears. ......................................................................................... 43
Figure 24:- six splined shaft .......................................................................................................... 47
Figure 25:- Stone collecting cabin of stone remover machine ..................................................... 51
Figure 26:- hydraulic stone dumping system ................................................................................ 52
Figure 27:- Standard Designations of Ball Bearing ...................................................................... 62

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 List of tables
Table 1:-concept screening ........................................................................................................... 16
Table 2:- concept scoring .............................................................................................................. 17
Table 3:- Design dimensions of bolt and nut according to IS: Reaffirmed 1996 ......................... 58
Table 4:-detailed specifications and summary of the stone remover ............................................ 63

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 List of symbols
P --- Power μ --- coefficient of friction
σy ---Yield stress M -- Bending moment
Pb --- Bearing pressure m -- Mass
D --- Draft force p – Pitch
t --- Thickness W – Weight
τ --shear stress Cv --- velocity factor
ν -- Poisson ratio τall -- Allowable shear stress
τ --shear stress δ--elongation
τnut -- Shear stress on the nut τmax—maximum shear
do--Outer diameter WW --- wearing load
di--Inner diameter WT --- tangential load
p --- Pressure V --- volume
S--- Forward speed m--- mass
θ --- Angle of inclination Pcr --- critical load
L --- length σl --- longitudinal stress
b --- Width σH --- hoop stress
ρ --- Density HB --- brinell hardness
V --- velocity α --- angle of contact
G --- Modulus of rigidity F.S—factor of safety
T --- No of teeth θp ---- pitch angle
List of some acronyms
PTO --- power take off shaft
GDP --- gross domestic product
PDD --- product design and development

viii
 CHAPTER ONE

INTRODUCTION

1.1. Introduction about stone remover machine from farm land

A stone remover is agricultural machine that is used in farming and landscaping to remove the
stones from the farm fields. The stones could be removed from the soil and ground surface to
improve crop production, prevent damage to other equipment’s used for farming and to improve
the appearance of the ground surface in preparation for a lawn.
The Ethiopian farm lands have many stones above the soils or mixed with hence we are
motivated to do as such to mechanize and introduce the stone remover machine as the result
maximization of their productivity. Especially, in Tigray there are many hectares of lands
covered by stones and their productivity is reduced due to the stones cover the fertilized soils.
This research relates to a machine for removing stones from farm fields and more particularly to
a machine pulled by a tractor, which dig up the stones, continuously transfers stones to a stone
hopper, and dumps stones from the stone hopper in a stone Storage area.

Farm fields in many areas have stones mixed with the soil. Stones are found in all shapes and
sizes. These stones interfere with growing plants, damage tillage tools, and damage harvesting
materials. Hence, it becomes essential to remove these stones from the field, improves the
structure and texture of the soil, increase the water holding capacity of the soil, and make the soil
easy for nursery preparation and other operation. These problems prevent the fiscal growth of
farmer and ultimately hamper the development of their farmland and family. Efficient, effective,
cheap and productive techniques have needed to strengthen the farmers.

It consists of differential, sprocket chain mechanism, chain drive, tine and trolley for collecting
stones. It is capable of collecting stones both small and big from a depth of 10-15 cm. So this
machine provides an effective way of collecting stones with great speed and accuracy.

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1.2. Background of the study
Agriculture in Ethiopia is the foundation of the country’s economy accounting for almost half of
gross domestic product (GDP) 83.9% of exports and 80% of the total employment. Agriculture is
an enterprise trained in all countries. From the earliest times, humankind has occupied in some
form of planting, herding, or gathering. Also Ethiopia has great agricultural potential because of
its vast areas of fertile land, diverse climate, generally adequate rainfall, and large labor pool.
Despite this potential, however, Ethiopian agriculture has remained underdeveloped. Because of
Poor economic base, low productivity, weak infrastructure and low level of technology have
been affecting. But still now the estimated 85% of the population is engaged in agriculture and
agricultural production.
Farming practices are heavily dependent on physical labor and labor shortage for farming work
make many farmers think of alternative practices for improving their farm productivity in a
sustainable manner.
Particularly in hilly regions, the fields are dotted with a number of small pebbles and stones
hindering farming activities such as land preparation and intercultural operations.

In dry areas, the soil contains a number of small pebbles and stones due to which farmers face
difficulties during land preparation. Hence it becomes essential to remove these pebbles. But the
most concerning part that arises to the farmer while removing pebbles is the shortage of labor
and the wages that need to be paid to them. Hence knowing all these problems, a mechanized
stone picker or remover is introduced which can be an alternative solution to overcome the
problem faced.

Manual labor takes time and is not effective as they can work for 3-4 hours at a stretch. Huge
amount of labor is engaged and its availability is the major problem faced by the farmers in
general, women’s are engaged in the removal of stone in dry land farming before the start of the
cropping season, and they undergo serious physical stress while doing such field operation.

Thus, there is a need for a smaller and efficient machine to pick up the stones with ease and also
which would be more accessible and also considerably cheaper. Entire machine is made from
local parts which were available locally so that the maintenance will be easy in future.

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1.3. Statement of problem and justification
Agriculture in Ethiopia is the foundation of the country’s economy but the amount of
productivity of crops is reduced due to many stones mixed with in the soil. Manual removal of
stones in farmlands undergoes serious physical stress and labor intensive while doing such field
operation. So as To ensure a more consistent yield or productivity there is a need for a smaller
and efficient machine to remove or pick up the stones with ease and also which would be more
accessible and also considerably cheaper.

Figure 1:- Farmlands with stones

1.4. Objectives

1.4.1. General objective

The main objective of the project is to design stone removing machine from farmland.

1.4.2. Specific objectives

 To propose detail engineering design for each components.
 To prepare detail part drawing and assembly drawing using SOLID WORKS 2016.
 To elaborate manufacturing and assembly procedures of the machine.

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1.5. Significance of the study
The significance of this study is:
Develop a good stone remover machine from farm lands.
This project will contribute a greater role on increasing production yield, reduction of labor and
reduction of lead-time during removing the stones for agricultural farmlands. We hope that this
paper will encourage the manufacturing industries to be used to this new design approach and to
adapt it as an effective selection and method that will benefit for farmers.

1.6. Scope of the study

The designed stone removing machine will be applied for stony geographical areas or lands.

The focus for this project will only on the design stage covering detail analysis of the machine
components by assessing the data using product design and development (PDD) concept up to
the modelling of the machine using SOLID WORKS 2016 software.

Hence, prototype and final production stages are not doable due to time, budget and equipment
constraints.

1.7. Limitations of the study

There are some limitations that were faced up on the study.
Some of them are:
 Unavailability of some data’s related to our works.
 Lack of sufficient related works about the problem solving machine.

1.8. Organization of the study

This paper consists of six chapters. The first chapter deals with the introduction while the second
chapter focuses on the review of literatures related to this paper. Chapter three is dealing with
methodologies. Chapter four comes with the machine part design analysis and chapter five
concerns with results and discussions. The next one, i.e. chapter six comprises conclusion,
recommendation and future works. The end of the paper will close up with drafting of
components, assembly, appendix and sets of references used throughout the research.

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 CHAPTER TWO

LITRATURE REVIEW

2.1 Agricultural equipment

Agricultural equipment is any kind of machinery used on a farm to help with farming. Stone
remover is one of the agricultural equipment that is used in agricultural fields. For farm lands to
be ready for cultivation and giving the needed products the stones with in the farmland have to
be removed.
2.2 What is stone remover machine?
A stone remover is agricultural equipment that is used in farming and landscaping where stones
need to be removed from the soil and ground surface to improve crop production, prevent
damage to other equipment’s used for farming, improve the appearance of the ground surface in
preparation for a lawn.
Lands with stones or with rock instead of fine soil are often less useful for crop. Thus, removing
stones from the soil also insures a more consistent yield. Additionally, using stone removers are
useful for crops forming tubers such as potatoes in the ground.
Joppa Hill, Amherst NH. Says that the design of stone gatherers relied upon metal teeth or pins
to grab or plow up the stones. The distance between the teeth governed the minimum size of the
stones that would be removed. Although the distance between teeth is not given, the close
spacing suggests they were intended for small stones. The overall design of these stone gatherers
suggests they were not designed to handle large stones. These stone gatherers likely gathered
small stones of similar size. (1)
Alois Weigel, Burnstad, N. Dak. Were invented a rock or stone picker, and more particularly to
a hydraulic stone picker for attachment to a tractor. The object of the invention is to provide a
stone or rock picker which can be readily attached to or detached from a tractor where by fields
or other areas can be quickly and easily cleaned of rocks, stones and the like, there being a means
provided for dumping the stones into a suitable receptacle when desired. (2)
Another typical design for a stone picker is disclosed in U.S. Pat. No. 5,027,906. This patent
discloses an apparatus with a pivoting fork and a stone collecting bin which may be drawn
behind a tractor. Designs of this nature lack the maneuverability of adaptions to the front-end

5
loader. The efficiency of operation is further reduced since the operator must divide his attention
between the trailing rock picker and the forward movement of the towing vehicle. (3)
Jacobs, in U.S. Pat. No. 2,980,189, discloses a rock picker for mounting to the side of a tractor
with a rear mounted stone collecting bin. This invention, however, cannot provide the
maneuverability of the adapted front-end loader design. Furthermore, the front wheels of the
tractor, being aligned with the stone picker, will hamper operation of the invention by rolling
over and further embedding the stones to be removed. (4)

2.3. Classifications of stone remover machines

According to power source used
1. Manually operated
Manually operated stone remover machines are used where areas with less stones. These are
operated by manual power. Most of manually operated stone removing techniques are used for
farmlands that have less stones as well as whenever the stones are not hard enough to remove.
These are not easily used for wide areas of agricultural lands.
2. Power assisted stone remover machines
According to the type of power used, stone remover machines can be classified as mechanically
and hydraulically operated.
Major advantages:
 This class of equipment offers a significant increase in harvest productivity
 Thus, these machines have the potential to meet the objective of reducing total harvesting
costs.
 Reduce seasonal demands, stabilize the labor force and increase the potential of pool of
laborers by improving working conditions.
Disadvantage
 Another power is required from the tractor to run the remover machine.

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2.1. Mechanically operated stone remover
These are stone remover machines; the removing technique was initiated by pulling through
tractors. The conveyor has driven by power take off shaft of the tractor. The rotating motion of
the power take off shaft was transmitted to the driving gear through shaft, gear reduction unit and
pulley mechanisms.

Figure 2:- mechanical operated stone remover

2.2 Hydraulic operated stone remover
This is a stone removing machine which is attached at the back of tractor and has strong springs
and the stone removing technique is hydraulically operated. As the middle shaft is rotated the
first digging blade will dig out the stones with in the farm land and the other blade will accepts,
is rotating continuously and the stones goes towards the back bucket (stone collector).

Figure 3:- hydraulically operated stone removers

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According to collector stone dumping mechanism
Stone remover machines can be classified according to their cabin used for collection of stones.

1. Manually opened collector

Here the removed stones that are collected at the back of the stone remover are removed by
simply opening the collector by our hands which can be fixed by pins or other fasteners.

2. Hydraulic dumping system

The collected stones are dumped by applying hydraulic force through the hoses attached to the
dumping cabin. These stone removers are small and cleaner series for working in limited space
and with small tractors. High strength iron chassis, driven by TF tractor and with a continuous
loading system, it is ideal for collecting stones up to 20 cm in diameter. It is much lighter than
conventional machines.

Figure 4:- hydraulically dumping stone removers

3. Conveyor operated dumping system
The stone remover machine in the figure below also has very advanced bucket conveyor and the
working principle of removing the stones is,two parallel vehicles are going over the land,the one
with removing machine attached to tractor and the other with the dumping car and as the blade is
removes the stones from the agricultural land is conveyed by the bucket conveyor to the
dumping vehicle.

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 Figure 5:- advanced bucket conveyor stone remover

4. According to conveying unit

Using slat conveyor
The removed stones can also be delivered to the stone collector by using slat conveyor. Used for
heavy loads or loads that might damage belts.
Advantages:
 This cannot easily damaged
 Can be used for heavy loads

Disadvantages:
 Conveys so Slow
 Noisy and complex system

Figure 6:- slat conveyor type stone remover

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Bucket conveyor
The machine below has a series of blade/bucket conveyor and chains at the sides of the collector
as the tractor pulls the stone remover.
Advantages
 Used easily to improve the appearance of the ground surface in preparation for a lawn.
Disadvantages:
 It can only remove and collects stones above the surface
 It can only collect stones that are very small in size.

Figure 7:- bucket conveyor

According to size of stone removed (diameter)
Stone removers can also be classified according to the size of the stones they remove.
Accordingly, the following are listed.
 Less than 20 mm diameter of stones
 From 20-35 mm
 From 35- 200 mm
 From 200-300 mm and More than 300mm of stones

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 CHAPTER THREE

METHODOLOGY
Before starting the project, information and data were collected from different data sources that
are very helpful to accomplish the project.

The methods employed to achieve the objectives of this thesis are the following:

In designing components of the machine

3.1. Data collection methodology

For designing this project both primary and secondary type of data collection is used.
Primary data collection methodology
The primary data was collected through observing components of the machine that are found
with in other machines, asking persons.
Secondary data collection methodology
The secondary data was collected from Books, written documents and the Internet.
Input Data`s
The collected data’s are based on the project problem and follow the data collection method.
According to the above methods, the necessary collected data which are used for the design
analysis are the following: -
I. data measured
The width of the tractor at the backside is approximately 2m.
II. The data taken from standardization
Speed of the power take of shaft=540 rpm
Power output from tractors =35hp-45hp

3.2. Concept generation and selection method

The science that is used to analyze the stone remover machine is through concept screening and
concept scoring by following the phases of product design and development (PDD).

3.3. Material Selection methods and materials used:

Considering design safety, the selection of material for machine to be designed is considering:

 Availability of materials

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  Suitability of the material for the required components
 Cost of the materials
 Substitutability of the materials
In modeling of the machine we use SOLID WORKS 2016 software.

For designing this project in addition to data sources many materials are used that are essential
for the completion of the project such as computer, papers, pen and drawings.

3.4. Design analyzing methodology

For analyzing purpose, the following are used
 Principles and techniques
 Figures and tables
 Drawings by software
 Simulation using ANSYS 19.0
The design calculations are basically depending on power transmitted to the stone remover
components and the stress, force on the components is calculated and checked their strength as
required, and in some components also the required dimensions are calculated from design
calculations point of view.
The analysis is through the following equations,
 The power transmitted using belts is given by: P = (T1 – T2) × V
T1
 Logarithmic relations of belt drives: 2.3log (T2) = μθ1

 Equivalent twisting moment equation: Te = √T 2 + M 2

1
 equivalent bending moment formula: Me = 2 [M + √M 2 + T 2 ]

 other formulas

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 CHAPTER FOUR

DESIGN ANALYSIS

4.1. Preliminary design analysis

4.1.1. Concept generation

Problem statement for concept generation
The farmers need an easy way of removing stones from the farmland. The machine needs to be
able to function in all-weather conditions and be corrosion resistant, safe in terms of structural
failure, and easily operated by a single employ.
Concept development
To conduct a comprehensive and thorough concept development by making a list of terms that
described the conceptual system as a whole, as well as separate conceptual subsystems. The
terms used are according how the stone is removed or filtered in order to make the land easy for
cultivation. The mechanisms offer filtering the stones. This is through internal and external
concept generation techniques.
Searching Externally:
The main aim of this external search is to find out the existing solutions for the existing problems
and to gather available information's about the competitive products and the technology they use.
The figures below are selected internal concepts.

Figure 8:- back side (left) and front end (right) stone removers
From the front end and the back end types of stone remover machines we select that back
end type.

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Search internally:
Here three concepts regarding of conveying system and dumping mechanism of the removed
stones are described for the stone remover machine.
 Three concepts are generated and the team has discussed on it
 Repeated concepts are rejected
 best concepts are selected

A. Concept one: rotary blade mechanism of digging stone

This removes the stones by applying rotational motion, meaning the blades are tend to rotate
continuously as the rotational motion coming from tractor is transmitted by the application of
bevel gear transmission.

Figure 9:- rotary blade operated digging stone

B. Concept two: chain conveyor mechanism
Here, the soil-stone separating unit consists of chain conveyor that is provided on the upper edge
of the blade. And then delivers to the backside of container. The chains are made up of number
of rigid links which are hinged together by pin joints in order to provide the necessary flexibility
for wrapping round the driving and driven wheels (sprockets). The conveyor is driven by PTO
shaft coming from the tractor.

14
 Figure 10:- chain conveyor mechanism stone remover

C. Concept three: three linkage raked joint mechanism

The stones are collected by the rake being dumped into the box or receptacle by a simultaneous
upward hinging of the rake and rearward tipping of the implement, both caused by the raising of
the front of the implement by the tractor drawbar.

Figure 11:- three linkages raked joint mechanism of stone removing

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 4.1.2. Concept screening and selection
In order to select the preferable concept of the proposed concept generated above, the next
procedures is followed; prepare the selection matrix, rate the concept, rank the concept, combine
and improve the concept and select preferable concept. A relative score of “better than” (+),
“same as” (0), or “worse than” (–) is placed in each cell of the matrix to represent how each
concept rates in comparison to the reference concept relative to the particular criterion. And
finally two different concepts have passed as illustrated below.

Table 1:-concept screening

No Selection criteria A. rotary blade B. chain C. raked joint

operated digging conveyor mechanism reference
stone mechanism
1 Easy of manufacturing + - + 0

2 Accurate and precise action 0 + - 0

3 Reliability 0 + - 0
4 Technological feasibility + + - 0

5 Low cost - - + 0

6 Digging capacity - + 0 0
7 Simplicity 0 - + 0
8 Less maintenance need + 0 + 0

9 Durability 0 + - 0
10 Performing speed + + - 0
Sum of +’s 4 6 4 0

Sum of 0’s 4 1 1 0
Sum of –‘s 2 3 5 0
Net score 2 3 -1 0
Rank 2 1 3 0
Continue Yes Yes No 0

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4.1.3. Concept scoring
To design the stone remover machine based on the above screening technique concept scoring is
used to compare the two different concepts.
Following the next procedures in table form, giving percentage for each of the selection
criteria’s, and giving relative values out of five for each of the criteria and then multiplying by
the value assigned in percent, finally summing up the values.
The whole stone remover system is made to be composed of among the generated and scoring
concepts that would yield maximum output, by following the procedures; finally, one different
concept system has passed as in the table below.

Table 2:- concept scoring

No Factor Percentage Using rotary blade using chain conveyor
value mechanism
Value out of Value out
5 of 5
1 Easy of 14 3 0.42 2 0.28
manufacturing
2 Accurate and 11 2 0.22 4 0.44
precise action
3 Reliability 6 2 0.12 4 0.24
4 Technological 5 5 0.25 5 0.25
feasibility
5 Low cost 13 4 0.52 3 0.39
6 Digging capacity 15 2 0.3 5 0.75

7 Simplicity 6 4 0.24 3 0.18

8 Less maintenance 12 3 0.36 3 0.36
need
9 Durability 8 2 0.16 4 0.32
10 Performing speed 10 3 0.3 5 0.5
Total 100% 2.89 3.71
Rank 2 1
Develop No Yes

17
The stone remover machine is designed based on the concept screened and concept scoring as
compared in the tables above.

4.2. Geometry and mechanism of the remover

Geometric and mechanism analysis is the way of analyzing the dimensions of the member of the
parts by standing from the designer‘s service of the product, standards, and assumptions. The
size, shape and profile of the stone remover machine mainly depends on over all width, height of
the tractors power takeoff shaft from ground, the length of three hitch links from tractor.
The machine is considers removing of large and small diameter stones with in the farm land.
Mechanism
The tracror is pulles to the remover machine as it is attached at the back side by 3 point
hitches.the power of tractor is transmitted to the remover by using power take off shaft. but the
rotational power coming should be at right angle hence bevel gears mechanism is used so as to
transfer to the conveyor shaft .therefore as the tractor pulls so does the remover conveys the
stones to the collector by filtering from soil at the crossrods of the conveyor.

Figure 12:- Free hand sketching of stone remover machine

18
4.3. Detail Parts Design Analysis
Material selection

Because the stone remover machine has different components so the material that is used for this
project must be good in corrosion prevention, and durable. And the materials are better to be cost
effective.

The following factors are considered while selecting the materials of the stone remover:

 Availability of the materials.

 Suitability of the materials for the working conditions in service, and
 The cost of the materials.
 Substitutability of the materials.

Design considerations
The components of stone remover were designed and elaborated based on the parameters like
functional requirements, engineering and general considerations.

The general assumptions made in the design of stone remover are the following:

 Speed of Power Take Off shaft has taken as 540 rpm.

 Average speed of operation of tractor in the field was kept as 2.5 km/h.
 Maximum soil resistance was considered as 0.75 kg/cm2.
 Type of soil generally, medium black with moisture content of 10.85%
 Coefficient of friction (µ) in un-ploughed soil was taken 0.85.
 The machine should dig stones from the field in 115 cm width and 12 cm depth.

19
Assessment of draft and power requirement
The draft requirement of the tractor operated stone remover would be estimated using factors
related to implement and the type of soil.

Cross section area of digging blade = length of blade × depth of cut = 115 × 12 = 1380 cm2

Maximum draft = cross section area of blade × soil resistance = 1380 × 0.75 = 1035 kg

Speed of travel = 2.5 km/h = 2500 m/h =0.69 m/s

The power required for the designed draft was estimated using following formula (Kepner et
al., 2005).

D×S
P=
1000

Where:

P = Power required (kW),

D = Maximum draft (N),

S = Forward speed. (m/s).

1035×9.81×0.69
p= = 7Kw = 9.4HP ………. Conversion (1hp=746W)
1000

So as this power is the power needed to draft the soil through digging blade, but the power
needed to operate on soil is affected by frictional resistance of the soil. And is calculated as
follows;

total power required

Horse power required to operate the implement in soil =
coefficient of friction
9.4
Horse power required to operate the implement in soil = 0.85 = 11.05HP

Hence, this implement could easily hitch and operated by most of tractors of 35 HP capacities.

20
4.3.1. Design of digging blade
The function of the blade of machine is to lift or dig up the layer of soil stones, partially or
completely break up the soil layer and deliver the resulting material to the subsequent working
components.
Material selected: quenched and tempered steel, cold rolled, ASTM A-148-65
Property: - σt = 724Mpa, σy = 586Mpa, and HB = 217
Known parameters:
 The width of the blade was decided 1.15 m on the basis of dimension of tread width of
the tractor of 35-45 hp range.
Assumptions:
 Assume the drafting load is distributed equally on the digging blade.
 The digging blade is assumed as it can dig up to 12 cm depth of cut.
 Angle of inclination ɵ = 22.4° and taking F.S=2
 As the blade is fixed at one end and free at the other, hence it is considered as cantilever
beam.
Analysis:
The digging force is acting at an angle of 22.4°
The drafting force on the blade acts horizontally with distributed force but by making in to point
load and applying on the half length of blade surface. So, the force can be resolved as following
in the diagram:

Figure 13:- Free body diagram and distribution of forces of digging blade
Length of digging blade (L) = d/sin22.4 = 12/sin22.4 = 31.5cm
Hence, the length of blade is 31.5 cm such that to cover 12cm depth of cut for digging.

21
 Maximum draft = cross section area of blade × soil resistance = 1380 × 0.75
= 1035 kg
Maximum draft in newton (FS) = 1035 × 9.81 = 10153.35N
FH = FS × cosɵ = 101153.35 × cos22.4 = 9387.24N
FP = FS × sinɵ = 101153.35 × sin22.4 = 3869.14N
The digging blade must be strong in bending and wearing.

Allowable stress for blade design

σy 586MPa
σall = = = 293MPa
F. S 2

Allowable shear stress for digging blade design

σy 586MPa
τall = = = 146.5MPa
2F. S 2×2

Since width (b) of the blade is known but the thickness (t) is unknown it has to be calculated
from design calculations.

The moment M due to cantilever beam of digging blade,

L
M = FP × = 3869.14 × 0.1575 = 2901.86Nm
2

bt3
IXX = , C = t/2
12

6M 6×2901.86×1000Nmm
t = √σ =√ = 7.19mm take 8mm
all ×b 293×1150

Therefore, the thickness of the digging blade is taken as 8mm. The tip of the blade is sharpened
to dig the soil easily.

The blade also subjected to shear stress due to force F which acts at its cross sectional area AC

AC = b × t = 1150 × 8 = 9200mm2

F 3869.14
τS = A P = =2.35Mpa
C 9200

Deformation diagrams with ANSYS R19.0 software

22
 Figure 14:- deformed shape of digging blade via ANSYS

Figure 15:- counter plot of deformation for digging blade

Elemental forces
***** POST1 ELEMENT TABLE LISTING *****
MINIMUM VALUES ELEM 1 VALUE -0.33983E+006

MAXIMUM VALUES ELEM 58 VALUE 0.43305E-015

From the counter plot deformation, the minimum deformation is 0.923×10-07m and the maximum
is 0.83×10-06m

Discussion: the stress induced is less than the allowable shear stress, so the design is
satisfactory. The selected material type is highly resistant to wear. From the deformation plot we
can also conclude that deformation is high from tip up to center of the blade.

23
4.3.2. Design of chain conveyor system
Conveyor: conveyor is equipment used to move materials over a fixed path between specific
points. Conveyors are used:
 When material is to be moved frequently or continuously between specific points.
 To move materials over a fixed path.
 When there is a sufficient flow volume to justify the fixed conveyor investment.
In the design of stone removing machine from farm land chain conveyor is selected for the
following reasons.
 Can be used for heavy loads or loads that might damage belts.
 Chain conveyor is reliable as well as durable in life time.
The chains are made up of number of rigid links which are hinged together by pin joints in order
to provide the necessary flexibility for warping round the driving and driven wheels. These
wheels have projecting teeth of special profile and fit into the corresponding recesses in the links
of the chain. The toothed wheels are known as sprocket wheels or simply sprockets. The
sprockets and the chain are thus constrained to move together without slipping and ensures
perfect velocity ratio.
The soil-stone separating unit consists of conveyor which was provided on the upper edge of the
blade.

4.3.2.1. Design of cross rods

Cross rod is attached with the conveyor system on both sides and these filter the stones and
convey to the collecting cabin.
Material selection

Since the rod is exposed to soil and moisture, so the material type used for rod must be corrosion
resistant. Therefore mild steel is selected.

Properties: –MS320

Yield strength=324MPa was selected.

Determination of volume flow of material on the conveyor: the volume of the material flow
on the conveyor was determined as follows:

Volume of soil mass = Area of coverage of the blade × forward speed of travel

24
 1.15 × 0.12 × 2500
= = 0.096m3 /s
3600

kg
Weight of soil to be handled = Volume of soil mass × Bulk density of soil ( ⁄m3 )
kg
= 0.096 × 1230 = 117.88 ⁄s
kg
Weight of stones to be handled = Volume of soil mass × Bulk density of stones ( ⁄m3 )
kg
= 0.096 × 865 = 83.04 ⁄s
Total material to be handled Qout = Weight of soil + Weight of stones = 117.88 + 83.04
𝐤𝐠⁄
= 𝟐𝟎𝟎. 𝟗𝟐 𝐬
Now equating the volume of material flow with volume of the conveyor by assuming that this
material will be spread uniformly on the conveyor, the following was obtained:
Qout = Bulk density of soil × width of conveyor × thickness of material (m) × speed of conveyor
200.92 = 1230 × w × 0.12 × 1.5
W (width) = 0.91 m = 𝟗𝟏 𝐜𝐦
L (length) = 1.05 m = 𝟏𝟎𝟓 𝐜𝐦
Therefore, the conveyor of 91 cm width and 105 cm length was selected.
The rods are spaced by some distance that is used to filter out the stones from the dug soil. The
rod was mounted as a pin at both sides to conveyor’s chain. Spacing between the cross rod was
50mm and the diameter of the rod was taken as 10mm.

Force analysis: Pull force is that force required for moving the chain, connected mechanical
parts and object being conveyed. Chain pull force required for the conveyor system is dependent
on the following factors:
1. Weight of soil carried
2. Chain conveyor weight
3. Coefficient of friction
Weight of soil and stone carried can be calculated as follows:

Soil flow rate = mass of soil/time, speed of conveyor = length of conveyor/time

Time = length of conveyor/speed of conveyor = 1.05/1.5 = 0.7 sec

Total mass of soil = Soil flow rate × time = 200Kg/s×0.7s = 140 kg

25
The conveyor is placed at 230 from horizontal so the pulling force can be calculated as:

Figure 16:- digging blade resolved forces free body diagram

Weight of chain conveyor also can be calculated as:

Length of conveyor is 2*1050mm = 2100mm

n = L/spacing between cross rods = 2100/50 = 42 cross rods

V = n × W × cross sectional area

= n×W×3.14×D2/4=42×0.91×3.14 (0.01)2/4

𝑉 = 0.003𝑚3

m = ρv = 0.003 × 7800 = 23.4kg

Where;

D = diameter of cross rod = 0.01m

W= length of cross rod = 1.05m

n = number of cross rod = 42

m = mass of cross rods and V = Total volume of cross rods

ρ = Density of mild steel –7800Kg/m3

The conveyor consists of cross rods and chains. The mass of chain has assumed as 10 kg.

26
Total mass of the conveyor = 23.4kg + 10 kg = 33.4kg

The overall mass of the soil, stone and the conveyor itself is 140+33.4 = 173.4kg

Over all coefficient of friction is due to bearing and rolling. So the overall coefficient of friction
has taken as 0.06. The conveyor is mounted at ∝e = 230 from horizontal so the pulling force can
be calculated as:

M = 173.4×9.81 = 1701.06N Where, M = total load of soil, stone and conveyor

FT = 𝑀 × 𝑠𝑖𝑛 ∝e = 1701.06×sin230 = 664.66N FT = tangential force

N = M × cos ∝e = 1701.06×cos230 = 1565.83N N = normal forcé

Ff = N × μ = 1565.83 × 0.06 = 93.95N Ff = frictional force

F = 𝐅𝐟 + FT = 93.95 + 664.66 = 758.61N F = total pulling force

F × V × CS 758.61N × 1.5 × 1.3

power required to drive the conveyor (P) = = = 𝟏. 𝟖𝟎𝐊𝐖
E 0.85

Where, Service factor Cs = 1.3

Transmission efficiency E= 0.85

Since the power required for driving the conveyor is 1.80 KW and the required power for
implement in soil is 11.05hp as calculated. Therefore, 35 HP (26KW) tractors are selected for the
design as they are commonly applied in agricultural fields.

PTO shaft power of the tractor which drives the chain conveyor has power of 22KW (30HP)
assuming 0.85 transmission efficiency. The shaft rotates at speed of 540 rpm with six splines on
it. And it has diameter of 1 3/8” (35mm).

Checking strength of cross rods

The cross rods are subjected to bending moment as they carry the stones and soils drafted.

Known values:

 Total mass of soil = Soil flow rate × time = 200Kg/s×0.7s = 140 kg as calculated before.

27
 W=140×9.81=1373.4N

 The numbers of cross rod are 42 as in the above but the current load is distributed on
42
( 2 = 21 𝑛𝑜 𝑜𝑓 𝑟𝑜𝑑𝑠) of the cross rods. And force is 1373.4N/21=65.4N

 Width and diameter of rod are 910mm and 10 mm respectively.

𝜎𝑦 324
𝜎𝑎𝑙𝑙 = = … … …. (𝑎𝑠𝑠𝑢𝑚𝑖𝑛𝑔 𝐹𝑆 = 3)
𝐹𝑆 3

= 108𝑀𝑃𝑎

𝑀𝐶 𝜋 × 𝑑4
𝜎𝑏 = 𝑤ℎ𝑒𝑟𝑒 𝐼 = for (circular moment of inertia)
𝐼 64

10 π × 104
and C = and I = = 490.88mm4
2 64

29757 × 5 910
σb = where M = 65.4N ×
490.88 2

σb = 60.62MPa

Discussion: the induced stress due bending is less than the allowable stress hence the design is
safe.

4.3.2.2. Design of Chain drive

Chains rarely fail because they do not have sufficient tensile strength. They most often fail in
wear or fatigue. In practice sprocket teeth wear allowing the chains to jump the
teeth. Manufacturers specify the chains based on the following parameters.

Chain Lubrication: Chain drive lubrication provides similar benefits to bearing journal
lubrication. The benefits include reduced friction, cooling, impact resistance at higher chain
speeds. The chain supplier generally provides recommendations for the lubrication requirements
for each chain drive. If suitable lubrication is not provided the capacity of the chain drive is
reduced.

Material selection:

Material type for sprocket: malleable cast iron –BM350

28
 Properties: yield strength=350MPa

Ultimate strength=621MPa

Material type for chain: mild steel –MS320

Properties: yield strength=350MPa

Assumptions: The assumptions made in the design of chain conveyor are as follows:

 Speed of conveyor that could separate soil and stone taken as 1.5m/s
 The conveyor has placed at 230 from horizontal for easily handling of the stones and
soils.
 FS= 3
 The conveyor’s chain has selected closed joint type chain.

Analysis:

 Since the diameters of the conveyor chain sprockets are equal so velocity ratio is 1.

Conveyor specifications: V = 1.5 m/s, N = 200r.p.m

R (pitch circle diameter of sprocket) = V/w = 1.5/20.94 = 72mm

 Length of conveyor has selected as 1.05 m. Centre distance between the sprockets,
C = 1050 − 2R = 1050 − 144 = 906mm
 In order to accommodate initial sag in the chain, the value of center distance is reduced
by 2 to 5 mm. correct center distance
x = 906mm − 4mm = 902mm
Let us take the standard pitch as p=60mm, since the minimum diameter of the stone filtered was
50mm and thickness of cross rod was10mm.

29
 Figure 17:- Chain drive

 We know that the number of chain links

T1 + T2 2x T2 − T1 2 P
K= + +( )
2 p 2π X

8 + 8 2 × 902 60
K= + +0×
2 60 902

K = 38

 Length of the chain

Lp = K × p
Lp = 38 × 60 = 2280mm
 The average velocity of the chain is given by

TPN
V=
60

Where, T = number of teeth of the sprockets, and

p = Pitch of the chain in meters

N = number of revolution per minute

30
 60V 60 × 1.5
T= = =8
PN 0.06 × 200

Roller diameter, d = 37 mm (selected from table)

Width of chain, b1= 36mm (selected from table)

Tooth profile parameters

1. Tooth flank radius (re)

re = 0.008 d (T + 180) … … … … … … … … … … … … . . . . (Maximum)
= 0.008 × 37(8 + 180) = 55.65 mm
= 0.12 d (T + 2) … … … … … … … … … … … … . . . . . . . . . . . . . . (Minimum)
= 0.12 ∗ 37(8 + 2) = 44.4 mm
Where d = Roller diameter, and T = Number of teeth.
2. Roller seating radius (ri)
ri = 0.505 d + 0.069(d)1/3 … … … … … … … … … … (maximum)
= 0.505 × 37 + 0.069 × (37)1/3
= 18.9mm
= 0.505 d … … … … … … … … … … … … … . . … . . . . . (Minimum)
= 0.505 × 37 = 18.69mm
3. Roller seating angle (α)
α = 140 – 90/T = 140 − 90/8 = 128.750 … … … … … … . (Maximum)

= 120 – 90/T = 108.750 … … … … … … … … … … … . (Minimum)

4. Tooth height above the pitch polygon (ha)
ha = 0625p + 0.5d + 0.8p/T = 0.625 × 60 + 0.5 × 37 + 0.8 × 60/8
= 62mm … … … … … … … … … … … … … … … max.
= 0.5 ∗ (60 – 37) = 0.5(60 – 37) = 11.5mm
5. The pitch circle diameter (D)
D = p cosec (180/T) = 60 × cosec (180/8) = 156.8mm
6. Top diameter (D0)
D0 = D + 1.25p – d = 94 + 1.25 × 60 – 37 = 132mm … … … . max.
= D + p (1 − 1.6/T) – d = 94 + 60 × ( 1 − 1.6/8) − 37 = 105mm … . . Min.

31
7. Root diameter = D − ri = 156.8 – 18.9 × 2 = 119mm
8. Tooth width (bf1) = 0.93b1 = 0.9 × 9.3 = 8.65mm
9. Tooth side radius (rx) = p = 60mm
10. Tooth side relief (ba) = 0.1p to 0.15p take 0.125
Then 0.125 × 60 = 7.5mm

Figure 18:- Tooth profile of sprocket

Figure 19:- Rim profile of sprocket

32
4.3.3. Design of conveyor Shaft
Shaft of the chain conveyor is used for the purpose of power transmission from the pulley belt
arrangement to the conveyor. The shaft has mounted on the pulley disc and the conveyor. It also
consists two sprockets which have mounted on it.
Material selection: Condition Annealed stainless steel 303
Properties: σu = 601𝑀𝑃𝑎 Yield strength σy =252𝑀𝑝𝑎
Modulus of Elasticity=193GPa
In order to have a good strength shaft material take fs=1.5
Allowable tensile stress for shaft design
σu 601MPa
σall = = = 400.7MPa
F. S 1.5
Allowable shear stress for shaft design
σy 252MPa
τall = = = 84MPa
2F. S 2 × 1.5
D, Diameter of the shaft
The torque transmitted to the driven pulley shaft is
Designed power x 60
T=
2πN4
22KW x 60
T= = 1050.4Nm
2π × 200
T = 1050.4 Nm
The driven pulley is overhung to the extent of 100mm=0.1m from the nearest bearing and is
mounted on a shaft. C=0.1m. Bending moment on the shaft due to the belt tensions has
M = (T1 + T2 + 2TC ) × C × n, where; n=number of belts
M = (1765.6N + 700.62N + 0) × 0.1 × 1 = 246.62 Nm
Hence, the equivalent twisting moment

Te = √T 2 + M 2
= √(1050.4 Nm)2 + (246.62Nm)2
= 1078.96Nm
We know that the equivalent twisting moment.

π
Te = × τ × D3
16

33
 16Te 1078.96 × 16 3
D3 = =( )m
πτ π × 84 × 106

D = 0.040m = 40.0mm

And also the equivalent bending moment is

1 π
Me = [M + √M 2 + T 2 ] = × σb × d3
2 32

1
Me = [246.62Nm + 1078.96Nm]
2

Me = 662.8Nm

π
Me = 662.8Nm = × σb × d3
32

662.8Nm × 32
d3 =
π × 400.7 × 106 N⁄m2

d=0.02563m

d=25.63mm

For design of shaft choose the bigger diameter, d=40.00mm

Check for safety with this diameter

T × 16
τindu =
π × D3

1050.4 × 16
τindu =
π × 0.0403

τindu = 83.6MPa

Discussion: Since τindu < τall this shows us the design is safe.
The conveyor has supported by sprocket having 72 mm pitch circle diameter at front, Centre and
rear side. The shaft of 40 mm diameter supports all the sprockets and the shaft has fitted in the
pulley.

34
4.3.4. Design of Universal (Hooke’s) Coupling
Coupling are used to transmit power from one shaft to another as shafts used are small in size
A universal or Hooke’s coupling is used to connect two shafts whose axes intersect at a small
angle. The inclination of the two shafts may be constant, but in actual practice, it varies when the
motion is transmitted from one shaft to another.

Figure 20:- Universal or hook coupling

In designing a universal coupling, the shaft diameter and the pin diameter is required to design is
obtained as discussed below. The other dimensions of the coupling are fixed by proportions as
shown in Fig. above
Material selection: malleable cast iron for shaft and stainless-steel AISI 303 for pin
Properties: σut = 621MPa and for pin=585MPa
σy = 483MPa For pin 240MPa
Brinell hardness, HB = 229 − 269
analysis:
Let d = Diameter of shaft 35 mm
dp = Diameter of pin, and
τand τ1 = Allowable shear stress for the material of the shaft and pin respectively.
σy 483MPa
τall = =
2F. S 2×3
τall = 80.5
We know that torque transmitted by the shafts,

π
T= × τ × d3
16

35
 π
T= × 80.5 × 353
16

T = 677688.17Nmm

Since the pin is in double shear, therefore the torque transmitted,

π
T= × (dp)2 × τ1 × d
4
π
677688.17Nmm = × (dp)2 × 60MPa × 35mm
4

From this equation of universal joint the pin diameter is dp = 14.33mm for more safe dp =
15mm.

4.3.5. Design of belt drive

Belts are used to transmit power from one shaft to another by means of pulleys which rotate at
the same speed or at different speeds.
The power was transmitted to shafts of conveyor of the stone removing machine through belt and
pulley mechanism.
The amount of power transmitted depends upon the following factors:
1. The velocity of the belt.
2. The tension under which the belt is placed on the pulleys.
3. The arc of contact between the belt and the smaller pulley.
4. The conditions under which the belt is used.

Types of Flat Belt Drives

The power from one pulley to another may be transmitted by any of the following types of belt
drives.
1. Open belt drive. The open belt drive, as shown in Fig. below, is used with shafts arranged
parallel and rotating in the same direction. In this case, the driver A pulls the belt from one side
(i.e. lower side RQ) and delivers it to the other side (i.e. upper side LM). Thus the tension in the
lower side belt will be more than that in the upper side belt. The lower side belt (because of more
tension) is known as tight side whereas the upper side belt (because of less tension) is known as
slack side, as shown in the Fig.

36
 Figure 21:- Open belt drive.
Material selection:

The most important material for flat belt is leather. The leather may be either oak-tanned or
mineral salt-tanned. But since this is applicable for high speed motion and due to its high cost,
we selected natural rubber belt due to its low cost and its availability.

Type of belt: rubber with properties of ρ=1140kg/m3

Permissible working stress =2.5 MPa.

Determining length of the belt

Assumptions:

 the center distance x=800mm, d1=100mm and d2=150mm

 The effect of creep is very small; therefore, it is generally neglected.

π (d1 − d2)2
L = (d1 + d2) + 2x +
2 4x

π (100mm − 150mm)2
L = (100mm + 150mm) + 2x +
2 4x

Therefore, the length of the belt will be; L=1993.5mm approximately; L=2m

Now let’s calculate the correct or the actual center distance x

π π 2
x = 0.25{[L − 2 (d1 + d2)]+√[L − 2 (d1 + d2)] + 2(d1 − d2)²}

37
 π π 2
x = 0.25{[2000 − 2 (100 + 150)]+√[2000 − 2 (100 + 150)] + 2(100 − 150)²}

x = 804.04mm

Hence the actual center distance is 804.04mm

Figure 22:- representations in open belt drive

Determination of angle of contact (contact arc)

When the two pulleys of different diameters are connected by means of an open belt as shown in
the figure above, then the angle of contact or lap(θ) at the smaller pulley must be taken in to
consideration.
While determining the angle of contact, it must be remembered that it is the angle of contact at
the smaller pulley, if both the pulleys are of the same material.
Let, r1=radius of larger pulley, here r1=150/2=75mm

r2=radius of smaller pulley i.e. r2=100/2=50mm

x = Distance between the centers of two pulleys (i.e. O1O2), and

L = Total length of the belt.

o1×M o1E−ME r1−r2

sinα = O1×02 = = That is, ME = O2 F
O1×02 x

r1−r2 75−50
sinα = sinα = 804.04
x

Sinα = 0.031

α = 1.78°

38
 From this α= 0.031rad
π
Therefore angle of contact or lap, θ1 = (180 − 2α) 180 rad (open belt drive)

θ1 = 3.08 rad Angle of contact at smaller pulley

Velocity Ratio of Belt Drive

It is the ratio between the velocities of the driver and the driven or follower.

N1 D2
Mathematically,N2 = D1 where, d1 = Diameter of the driver,

d2 = Diameter of the follower,

N1 = Speed of the driver in r. p. m., and
N2 = Speed of the follower in r. p. m.

Speed of the belt, Vb = (1 − s)V where s is the slip and V is the speed of the driver pulley which
πd1N1
is given by: V = 60

π × 100 × 300
V=
60
= 1570.8mm/s
V = 1.57m/s
Hence Speed of the belt, Vb = (1 − 0.02)1.57
Vb = 1.54m/s
Determining the tight and slack side tensions T1, and T2
The effective turning (driving) force at the circumference of the follower is the difference
between the two tensions i.e. T1 – T2.
The power transmitted is given by: P = (T1 – T2) × V
And the torque exerted on the driving pulley is (T1 – T2) × r1
Similarly, the torque exerted on the driven pulley i.e. follower is (T1 – T2) × r2
Since the power coming is transmitted equally by assuming no losses the power is 1.64kw as
calculated before.
P = (T1 – T2) × V
22KW = (T1 – T2) × 1.54
(T1 – T2) = 14285.7N

39
And also from the logarithmic relation
T1
2.3log ( ) = μθ1
T2
T1
2.3log ( ) = 0.3 × 3.08rad
T2
T1
log ( ) = 0.40173913
T2
T1
( ) = 2.52
T2
From this T1 = 2.52T2
By solving simultaneously T2=9398.5N and T1=23684.2N
From the concept of maximum tension T = T1 + TC = σ × b × t by neglecting centrifugal
tension and assuming thickness of the belt is 8mm. (from standard)
T1
bt =
σall
23684.2N
b × 8mm =
2.5MPa
From this; calculating b=88.28mm taking from standard and then the desired width is =90mm.
Discussion: the designed flat belt is wide so as to have high contact with the pulley and create
friction.

4.3.6. Design of flat belt pulley

Pulleys are used to transmit power from one shaft to another by means of flat belts, V-belts or
ropes.
Following are the various types of pulleys for flat belts:
 Cast iron pulleys,
 Steel pulleys,
 Wooden pulleys, Paper pulleys, and. Fast and loose pulleys
From these cast iron pulley is selected, Because of their low cost and good friction and low wear
characteristics.
Dimensions of pulley
Since the assumed diameters of the pulleys are less than 200 mm it is not subjected to centrifugal
tension.

40
Width of pulley: If the width of the belt is known, then width of the pulley or face of the pulley
(B) is taken 25% greater than the width of belt. B = 1.25b; Where b = Width of belt
Therefore, the width of pulley is calculated as:
B = 1.25 × 90mm
B = 112.5mm
Dimensions of arms
The pulleys less than 200 mm diameter are made with solid disc instead of arms. Hence as
described earlier the diameters of the two pulleys are 100 mm and 150 mm therefore, no need of
arms. The thickness of the solid web is taken equal to the thickness of rim measured at the
Centre of the pulley face.

4.3.7. Design of key

A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley to connect
these together in order to prevent relative motion between them. It is always inserted parallel to
the shaft.
Keys are used as temporary fastening and are subjected to considerable crushing and shearing
stresses. A keyway is a slot or recess in a shaft and hub of pulley to accommodate a key.
There are different types of keys. from these, we have selected Sunk keys because, sunk keys are
easy to handle and to remove, the sunk keys can be of the Rectangular, Square, Parallel sunk key
or gib-head key.

Type of key: rectangular key selected all over the remover machine
Material selected: mild steel
Properties: σy = 600Mpa
τ = 320 Mpa
F.S= 2.5
From standard table, for shaft diameter d=40mm, the corresponding value of the key width and
thickness are:
W = 14 mm
τ
t = 9mm from the above parameters also τall = F.S. = 128Mpa

σll = 240Mpa

41
Now the length of the key is obtained by considering the key in shearing and crushing.
Considering shearing of the key (torque transmitted) of the key;
d
T=F×r⤇L×w×τ×
2
40mm
T = L × 14mm × 128MPa ×
2
Torsional shearing strength
π
Torsional shearing strength (or torque transmitted) of the shaft, T = 16 τ × d³
π
T= 128 × 40³
16
From this the torque is T=1608495.44Nmm, then substituting to the above formula;
40mm
1608495.44Nmm = L × 14mm × 128MPa ×
2
Calculating for L gives; 𝐋 = 𝟒𝟒. 𝟖𝟖𝐦𝐦
Crushing strength of the key
Considering crushing strength of the key, we know that shearing strength (or torque transmitted)
of the key,
d
T = L × t/2 × σc ×
2
40mm
1608495.44Nmm = L × 9mm/2 × 240MPa ×
2
𝐋 = 𝟕𝟒. 𝟒𝟕𝐦𝐦
Taking larger of the two values, we have length of key, L = 74.47mm say L=75mm

4.3.8. Design of bevel Gears

The power coming from the tractor has transmitted to shaft through bevel gear mechanism.
Bevel gears are used for transmitting power at a constant velocity ratio between two shafts
whose axes intersect at a certain angle
Material selected: Gray cast iron for both pinion and gear

Properties: yield strength=483MPa

Ultimate strength=621MPa

Brinell hardness= 229-269

42
 Elastic modulus EP = EG = 84 KN/mm2

Known parameters: power output =22Kw

Assumptions: take surface endurance limit as 630 MPa
And taking of factor of safety, F.S= 3
T1 = No. of teeth on driving gear =10
T2 = No. of teeth on driven gear=18
the gears are at right angle
Assume module, m =6
The tooth profiles of the gears are of 14 1/2º composite form (pressure angle=14 1/2°)

Figure 23:- Terms used in bevel gears.

Analysis:
N T
V. R = N1 = T2
2 1

Where, N1 = No. of revolution of driving gear (pinion) =540 rpm

N2 = No. of revolution of driven gear
T1 = No. of teeth on driving gear (10)
T2 = No. of teeth on driven gear (18)

43
 540 18
VR = =
N2 10
N2 = 300rpm
Since the shafts are at right angles, therefore pitch angle for the pinion,

1 1
θP1 = tan−1 ( ) = tan−1 ( ) = 29.05°
V. R 1.8

And pitch angle for the gear,

θP2 = 900 − 29.050 = 60.950

Formative or Equivalent Number of Teeth for Bevel Gears (Tredgold’s Approximation)

We know that formative number of teeth for pinion is given by:

DP
TEP = TP sec θP1 = sec θP1
m

Dp
= sec 29.050 = 0.19 × Dp → module, m = 6
6

From this equivalent number of teeth of pinion is TEP = TP sec θP1

=11.44

TEP = 0.19 × Dp From this equivalent number of teeth the diameter of the pinion gear is then
calculated as:

0.19 × Dp = 11.44

Dp = 60mm

And equivalent (formative) number of teeth on the gear,

DG DG
TEG = TG sec θP2 = sec θP2 = sec 60.950 = 0.343 × DG
m 6

TEG = TG sec θP2

= 37.07

From this also the diameter of gear; 37.07 = 0.343 × DG

44
 DG = 108𝑚𝑚

Since both the gears are made of the same material, therefore pinion is the weaker. Thus, the
design should based upon the pinion.

We know that tooth form factor for the pinion having 14 1/20 composite teeth,

0.684 0.684 × 6
y ′ P = 0.124 − = 0.124 − = 0.105
TEP 11.45

And pitch line velocity,

πDP NP π × 0.06 × 540

v= = = 1.7m/s
60 60

Taking velocity factor,

6 6
cv = = = 0.78
6 + v 6 + 1.7

We know that length of the pitch cone element or slant height of the pitch cone,

DG 2 DP
L = √( ) + ( )2
2 2

108 2 60
L = √( ) + ( )2
2 2

L = √(54)2 + (30)2

𝐋 = 𝟔𝟏. 𝟕𝟕 𝐦𝐦 𝐬𝐚𝐲 𝐋 = 𝟔𝟐𝐦𝐦

Assuming the face width (b) as 1/3rd of the slant height of the pitch cone (L), therefore

L 62
b= = mm = 21 mm
3 3

We know that Torque on the pinion,

P × 60 22KW × 103 × 60
T= = = 389 Nm
2π × NP 2π × 540

45
Tangential load on the pinion,

T 29
WT = = = 𝟗𝟔𝟔. 𝟔𝟕 𝐍
DP⁄ 60mm
2 2

Checking the gears for the wear,

We know that the load-stress factor,

(σes )2 sin ∅ 1 1
K= [ + ]
1.4 EP EG

(630)2 sin 14 1/20 1 1

K= [ + ]
1.4 84 × 103 84 × 103

K = 1.687

And ratio factor,

2TEG 2 × 37.07
Q= = = 1.53
TEG + TEP 37.07 + 11.44

Maximum or limiting load for wear,

Dp . b. Q. K
Ww =
cos θP1

60mm ∗ 21mm ∗ 1.53 ∗ 1.687

Ww =
cos 29.050

𝐖𝐰 = 𝟑𝟕𝟐𝟎𝐍

The proportions for the bevel gears are:

 Addendum, a = 1 × m = 1 × 6, a = 6
 Dedendum, d = 1.2 × m = 1.2 × 6, d = 7.2
 Clearance = 0.2 × m = 0.2 × 6, C = 1.2
 Working depth = 2 m = 2 × 6, depth = 12
 Thickness of tooth = 1.5708 × m, t = 9.4248
Where, m is the module.
Discussion: since the maximum load for wear is much more than the tangential load (WT),
therefore the design is satisfactory from the consideration of wear.

46
4.3.9. Design of shaft for Bevel Gears

Drive shaft is used for the purpose of power transmission from the tractor output to the bevel
gear connection. The power that comes from tractor is through universal joint connection to the
bevel gear by six spline shaft. Splined shafts are when the keys are made integral with the shaft
which fits in the keyways broached in the hub. The splined shafts are relatively stronger than
shafts having a single keyway.

Material selection: Condition annealed stainless steel ASTM A148-1

Tensile strength: 620𝑀𝑃𝑎 and E=193GPa

Yield strength σy = 414𝑀𝑝𝑎

Figure 24:- six splined shaft

Assumptions: pinion shaft overhangs by 100 mm
In order to have a good strength shaft material take factor of safety1.5

Analysis: the shaft is subjected to bending and twisting moment

Allowable tensile stress for shaft design

σy 414MPa
σall = = = 276MPa
F. S 1.5

Allowable shear stress for shaft design

σy 414MPa
τall = = = 138MPa
2F. S 2 × 1.5

d, diameter of the shaft

47
The torque transmitted to the bevel gear is

Designed power x 60
T=
2πN4

22KW x 60
T= = 389Nm
2π × 540

𝐓 = 𝟑𝟖𝟗𝟎𝟎𝟎𝐍𝐦𝐦

Find the tangential force (WT) acting at the mean radius (Rm) of the pinion. We know that
T
WT =
Rm
Length of the pitch cone element is calculated before as L=62mm,
Hence the mean radius of the pinion is:
b Dp
Rm = (L − )
2 2L
21mm 60mm
Rm = (62mm − )
2 2 × 62
From this, 𝐑𝐦 = 𝟐𝟒. 𝟗𝟐𝐦𝐦

We know that tangential force acting at the mean radius,

T
WT =
Rm
389000Nmm
WT =
24.92mm

𝐖𝐓 = 𝟏𝟓𝟔𝟎𝟗. 𝟗𝟓𝐍
Axial force acting on the pinion shaft,

WRH= WT × tan∅ × sinθp1

WRH= 15609.95N × tan14 1/2° × sin29.05°

WRH= 1960.26N

And radial force acting on the pinion shaft,

WRV= WT × tan∅ × cosθp1 = 15609.95N × tan14 1/2° × cos29.05°

WRV= 3529.1N

Therefore, bending moment due to WRH and WRV, will be

M1 = WRV × Overhang – WRH × Rm = 3529.1N × 100mm − 1960.26N × 24.92mm

48
 𝐌𝟏 = 𝟑𝟎𝟒𝟎𝟔𝟎. 𝟑𝟐𝐍𝐦𝐦

And bending moment due to WT,

M2 = WT × Overhang = 15609.95N × 100mm
𝐌𝟐 = 𝟏𝟓𝟔𝟎𝟗𝟗𝟓𝐍𝐦𝐦
Resultant bending moment;M = √(M1 )2 + (M2 )2

= √(304060.32)2 + (1560995)2

M = 1590332.7Nmm

Since the shaft is subjected to twisting moment (T) and bending moment (M), therefore
equivalent twisting moment,
Te = √(M)2 + (T)2
= √(1590332.7Nmm)2 + (389000Nmm)2
Te = 1637216.9Nmm = 1637.2Nm
π
We also know that equivalent twisting moment, (Te) Te = 16 × τ × D3

16T 1637.2N × 16
D3 = =( ) m3
πτ π × 138N × 106

D = 0.03278m = 32.8mm

In order for becoming the same with the power take of shaft standard for 540 rpm tractor take
d=35mm. Therefore six spline shaft diameter is chosen D=35mm.

Check for safety with this diameter,

σall = 276MPa

τall = 138MPa

T × 16 389Nm × 16
τindu = =
π × D3 π × 0.0353

τindu = 46207830.47Pa

τindu = 46.2MPa

Maximum shear transmitted though the spline shaft is calculated in the above. But, the splined
has to be check in shearing and crushing stress.

49
Assumption: length of the splined part=60mm

Considering shearing of the splines:

d
T = L× w×τ ×
2

Where, w is width of the spline,

That is,d = 0.90 × 35mm → 31.5mm and w = 4mm from standard parameters of six spline
shafts.

2T 2 × 389000Nmm
τ = =
(L × W × d) (60mm × 4mm × 35mm)

τ = 92.61MPa

The induced shear in the spline is less than the allowable shear (92.61MPa<138MPa), so the
design of spline for shearing is safe.

Now, let’s check crushing of splines

t d
T = L× × 𝛔𝐜 ×
2 2

4×T 4 × 389000Nmm
𝛔𝐜 = =
L × t × d 60mm × 4mm × 35mm

σc = 185.24MPa

Since, σc is less than σall (σc=185.24MPa <σall=276MPa) therefore the design of spline for
crushing is safe.

Discussion: the induced shear stress in the shaft, crushing and shearing stresses induced in the
splines due to the torsional effect is crosschecked with the allowable stresses and come up
smaller. This shows us the design is safe.

50
Since the design of pinion gear shaft is performed and concluded as the design is safe the
therefore, design of gear shaft is also safe as pinion shaft is subjected to higher torsional stress
than the gear (large gear).

4.3.10. Design of stone collector

The stone collecting trolley is used for collection of stones. It is provided at the rear side of the
conveyor. The collected stones conveyed by conveyor and dropped into the collecting trolley
which is supported by two rubber wheels and hydraulic system is provided in the rear side of
trolley for the unloading of the filled stones.
Material selected: gray cast iron, ASTM 30
Property: Ultimate tensile strength = 214 Mpa
Ultimate shear strength = 276 Mpa
Yield Strength = 178 Mpa
Assumptions: bulk density of stones= 1.59Kg/m3 [A.Rahmouni]
Vertical height of the collector=35cm
Length of 120cm
Width =50 mm
Taking F.S=2
Analysis: the collecting cabin is subjected to shearing stress at the pin connection and also
compressive stress due the load of the stones.
Finding allowable stresses
σy 178
 σall = F.S = 2
= 89MPa
σy
 τall = 2F.S = 44.5MPa

Figure 25:- Stone collecting cabin of stone remover machine

51
Volume of the collector V = A × h to find the volume let we divide the collector in to
rectangular and triangular to which the collector is approached to.
Volume of rectangular, V= b×w×h
Vr = 10cm × 35cm × 120cm
= 42000cm3
1
Volume of triangular, V = (2 b × h × w) × 2
1
= ( × 20cm × 35cm × 120cm) × 2
2
= 84000cm3
Total volume, Vt = 42000cm3 + 84000cm3
= 126000cm3 = 0.126m3
To find the mass of stones ms = ρ × v
= 0.126m3 × 1590Kg/m3
ms = 200.34Kg
Assuming small amount of mass of soil is passes with in the soil, the total mass on the collector
mtotal = 205Kg
Total weight on the collector, W = 205kg × 9.81m
W = 2011.05N
This is vital for designing of hydraulic cylinder, which is used for dumping of the collected
stones.

Figure 26:- hydraulic stone dumping system

To find reaction force at the cylindrical rod

52
 ∑ MA = 0, Fh × sin40 × 35cm − Fg × 10cm

Fh = 894N
Checking for Shearing at the pin like connection:
Since the hydraulic force has insignificant effect on the two side connections, the shearing stress
is calculated based on the load on the bin.
Assume diameter of pin=40mm
And length of the pin enclose=1.5×d
F
τ= Where Ac is crosectional area
Ac

F/2 1005.53N
τind = π = π
2 2
4d 4 × (40mm)
τind =0.80MPa
Thickness of the enclosure:
F 1005.53
τall = =
Ac t×l

1005.53
44.5MPa =
t × 60
t = 3.77mm For more safe t=5mm
Checking for crushing (bearing) stress at the enclosure:
F/2 1005.53N
σb = =
π×d×l π × 40mm × 60mm
σb = 133.3KPa
Checking for compression stress on the bucket due to the load
F 2011.05N
σc = = =
Arec + Atria 2(1 × 20 × 35) + (35 × 20)
2
σc = 19152.9N/m2
σc = 19.15KPa
Discussion: the induced shearing, bearing and compressive stress due to the assumed loads is
less than the allowable stress. Hence the design is safe.

53
4.3.11. Design of hydraulic system of dumping
Pascal’s law states that when a confined fluid is placed under pressure, the pressure is
transmitted equally in all directions and on all faces of the container. This is the principle used to
retract the piston rods on a hydraulic cylinder. Oil from the reservoir is drawn past a check ball
into the piston cylinder by tractor operator and as the piston rod is retracts; the stones collected
within the bin will be removed in stone removing area.
Design of piston rod

Material selected: carbon steel, cold rolled, AISI 1035,

Property: - σy = 462Mpa, σut = 586Mpa, E = 207Gpa and G = 89Gpa

It has the following properties

Excellent in machinability.
High resistance to wear
High compressive stress
σy 462MPa
σall = = =231MPa
fs 2

 Assume diameter of piston rod 40 mm lengths of 104.4cm

 Bore diameter=90mm

 Bore thickness=4cm

 Length of piston rod=45cm

Has to be checked for compression stress

Fh 894N
σc = = π×402
= 0.71MPa Which is less than the allowable stress..
A
4

The pressure induced due to the force of 894N

F 894
P= = = 140.53KPa
A π × 902
4

To check for buckling uses Rankin’s theory formula. And the two plunger ends considered to be
fixed.

54
 σcr
Pcr =
Le
1+∝ ( K )²

Where; Pcr = critical load, k= Radius of gyration, A= cross-sectional area, ∝=Rankin’s

constant=1/7500

πd2 π×402
A= = = 1256.64mm2
4 4

πd4
K = √I/A Where I = moment of inertia I= 64 =125663.71mm4

K = √I/A

K=9.999 approximately K=10

Critical (safe) load, 𝐏cr = Fmax x F. S = 894N x2

𝐏cr = 1788N
a
Le = 2< 45cm Therefore, Le = 22.5cm=225mm, maximum

Substituting all the result value to the formula

σcr
Pcr =
Le
1+∝ ( K )²

σcr
1788N =
225mm
1 + 1/7500( 10 )²

σcr = 189.5MPa

Discussion: 189.5MPa<σall = 231MPa hence, design is safe in compression and in crushing

stress.

Design of cylinder

Cylinder is designed based on the hoop stress and longitudinal stress produced inside the
cylinder bore due to the internal pressure and maximum sheer stress applied on it because of
frictions created when there are losses in cylinder due to:

 Oil pressure inside cylinder

55
  Pre-load of seal and

 Size of the sealing surface

Selected material: - malleable cast iron, ASTM, grade 47

Properties: - σy=345Mpa, σt=485Mpa and factor of safety=2

σy 345Mpa
σall = = = 172.5MPa
FS 2
σy
τall = = 86.25MPa
2×2

Then we can know that the thickness of the cylinder

Assume the optimum internal diameter of the cylinder at the load is 90mm.

r1=90/2=45mm

σall+p 172.5MPa+0.1405MPa
t = r1 × [√σall−p −1] t = 45mm × [√172.5MPa−0.1405MPa −1]

From this t = 2.8mm ≅ 3mm

External diameter (Do) = Di + (2 x t) = 90 + (2 x 3) = 𝟗𝟔𝐦𝐦

If the wall thickness of the shell (t) is less than 1/10 of the diameter of the shell (d), then it is
called a thin shell.
1
3mm<10 × 90

3 < 9 Thin cylinder

Check for longitudinal stress,

p × Di 140.53KPa × 90mm
σl = =
4t 4 × 2.8mm

= 𝟏𝟏𝟐𝟗. 𝟑𝐊𝐏𝐚 = 𝟏. 𝟏𝟑𝐌𝐏𝐚

Check for hoop stress of the cylinder part,

p × Di 140.53KPa × 90mm
σh= =
2t 2 × 2.8mm

= 𝟐𝟐𝟓𝟖. 𝟓𝟐𝐊𝐏𝐚 = 𝟐. 𝟐𝟔𝐌𝐏𝐚

56
 After having both hoop and longitudinal stress produced due to the internal pressure it
possible to determine the maximum shear stress created in the internal part of the
cylinder.

σ1 − σ2
τmax =
2

Where σ1 = σh and σ2 = σl and σ1 > σ2

2.26MPa − 1.13MPa
τmax =
2

=0.565MPa=565kpa

From the material property data the allowable shear stress is 86.25MPa

τmax < τall ….. 565kpa < 86.25MPa Design is safe.

Letting from the above force analyses max length of cylinder is 52.2cm=522mm

The induced shear stress created over the cylinder surface is given by:

Fh
τind =
π×d×l
894N
τind =
π × 90mm × 522mm

= 6.06KPa

Discussion: Since the induced shear stress is less than the allowable shear stress it is safe!!

And Hoop stress is higher than the longitudinal stress induced due to the pressure inside the
cylinder.4.3.12. Design of Bolt and Nut

The joining of removable machine and structural element is commonly accomplished by means
of threaded bolts and nuts.

A bolt is a threaded fastener designed to pass through holes in the mating members and to be
secured by tightening a nut from the end opposite the head of the bolt. And these bolts and nuts
for this machine are used to hold/fasten frame of the remover with the digging blade also to
fasten the bearing journals with the frame.

57
Design of bolt
Material selection: It is recommended that the bolts should consist of harder material than the
Components to be connected.
Selected material: carbon steel AISI 303
Mechanical properties of the selected material are:
σut =585Mpa σb = 2.5N/mm2
σy=240Mpa Brinellhardness = 88 and Reduction in area =55%
Assumption: the design of bolts and nuts is performed based on the applied external forces. The
initial stress induced due to screwing up forces is negligible.
Taking factor of safety =3
Analysis: -the design of bolts is analyzed based on the higher applied external force (draft force).
The bolt is subjected to shear stress and bearing stress.
Known value; Maximum draft force = 10153.35N

Considering, the shearing stress of the bolt and the applied force.

π
Fresisting = × (dc)2 × τ × n
4
π
10153.35N = × (dc)2 × 60MPa × 4
4

dc = 8.99mm

Taking from standard and take dc=12mm

According to this core diameter the other specifications are below.

Table 3:- Design dimensions of bolt and nut according to IS: Reaffirmed 1996 (5)
Designation Pitch Major or Effective or Minor or Depth of thread Stress
nominal pitch diameter core (bolt) mm area mm2
(mm)
diameter nut and nut and bolt diameter
bolt(d=D) mm (dp) mm Bolt Nut
(dc)

M 12 1.75 12.0 10.863 9.858 10.106 1.074 84.0

58
Strength analysis
Design based on shear stress across threads
p
𝛕= πdc×b×n where, b: is width of the threaded section at root

b=p/2 where p is pitch from the above table 1.75mm

Therefore, b=1.75/2 =0.875mm
𝟏𝟎𝟏𝟓𝟑.𝟑𝟓𝐍
𝛕 = 𝛑×9.858×𝟎.𝟖𝟕𝟓×𝟒 from this 𝛕= 9.36Mpa

Discussion: 60Mpa >9.36Mpa meaning that τall is greater than the shear stress induced by the
force. Therefore, design is safe!
Design based on Compression or crushing stress on threads
p
σc= π(do2 −dc2)×n
10153.35N
= π(122 −9.8582 )×4

Crushing stress = 17.26Mpa

Checking its strength
σy 240
σall = F.S = =80MPa taking a factor of safety =3
3

Discussion: σall>σc It is safe!

Design of Nut
Nut is the type of fastener that is used for tightening two or more than two pieces together.
Analysis: The nut is subjective to compressive and shearing stresses.
Selected material type: leaded tin bronze UNS No C 92200
Mechanical properties:σut =276Mpa σb =2.5Mpa
σy =138Mpa Hardness =65
Assumptions: The load is distributed uniformly over the cross sectional area of the nut.
Lnut = 1.5 × do
=1.5×12
= 18mm
From the above calculation of bolt, the required core diameter of nut is taken from 12 mm core
diameter of bolt;
Strength analysis
The nut threads are subjected to crushing or compressive and shear stresses.

59
 Design based on compressive stress

Considering crushing failure, we have;

π
F = n (d2o − d2c )σnut
4
π
10153.35N = (4) (12² − 9.8582 )σnut
4

σnut = 69.02MPa

Discussion:σnut <σall and 69.02Mpa < 80Mpa Therefore, the design of nut is safe based on
compressive.

4.3.13. Design of frame

The frame is meant for holding different components of stone remover machine. It is subjected to
bending, tension, and vibrations. The frame was fabricated using L-section angle iron for
mounting digging blade, separating unit and power transmission unit. The components were
fastened on the main frame using bolts and nuts. The frame was provided with three hitch points
to mount the machine on tractor. The three-point hitch using 75 mm × 5 mm flat. The rear end of
the frame was supported on two wheels for proper stability and easy transportation of the
machine.

Assumed dimensions of the frame three-point hitch are length of 75mm and width of 5mm flat.

Average cleared area of the farm land

Known parameters:
 Speed of tractor=2.5Km/hr.
 Width of stone remover blade =1.15m
Assuming 8 hours working in a day, the machine that can dig out stones from land can be
calculated as;
2500𝑚
Area covered by the stone remover machine = × 1.15𝑚
ℎ

2875𝑚2
𝐴=
ℎ
1 hectare=10000m2
By using this machine, a farmer can remove 2 hectares in a day.

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4.4. Selected elements of the machine

4.4.1. Selection of bearings

A bearing is a machine element which supports another moving machine element (known as
journal). It permits a relative motion between the contact surfaces of the members, while
carrying the load.
Bearing permit smooth, low-friction movement between two surfaces. The movement can be either
rotary (a shaft rotating with in a mount) or linear (one surface moving along another). Bearing can
employ either a sliding or a rolling action. Bearing based on rolling action are called rolling-element
bearings. Those based on sliding action are called plain bearings.
Though the bearings may be classified in many ways, yet the following are important

Depending upon the direction of load to be supported:

(a) Radial bearings: - the load acts perpendicular to the direction of motion of the moving
element.

(b) Thrust bearings: - the load acts along the axis of rotation

Depending upon the nature of contact:

a) Sliding contact bearings: - sliding takes place along the surfaces of contact between the
moving element and the fixed element.
b) Rolling contact bearings: - the steel balls or rollers are interposed between the moving and
fixed elements. The balls offer rolling friction at two points for each ball or roller. Therefore this
project deals depending upon the nature of contact, because it includes moving and fixed
elements as a result it is suitable to choose rolling contact bearing.

The most common ball bearings are available in four series as follows:
1. Extra light (100), 2. Light (200),
3. Medium (300), 4. Heavy (400)

The extra light and light series are used where the loads are moderate and shaft sizes are
comparatively large and also where available space is limited. Therefore, the project uses light
series ball bearing as the diameter of the shaft designed is in the range of light duty.

From table27.1 Gupta text book, For Diameter of shaft (bore diameter), di = 40mm

Bearing No. is 208 with bore diameter =40mm, outer diameter=80mm and width of 18mm

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 Figure 27:- Standard Designations of Ball Bearing

4.4.2. Rubber wheels

The rubber wheels play a major role when the machine is in idle condition. The wheels are
connected at the end of the trolley. These wheels support the entire frame of the machine.

4.4.3. Hydraulic Fluid and lines

Hydraulic fluid must be essentially non-compressible to be able to transmit power
instantaneously from one part of the system to another. At the same time, it should lubricate the
moving parts to reduce friction loss and cool the components so that the heat generated does not
lead to fire hazards. It also helps in removing the contaminants to filter. The most common liquid
used in hydraulic systems is petroleum oil because it is only very slightly compressible.

Pipe, tubes and hoses, along with the fittings or connectors, constitute the conducting lines that
carry hydraulic fluid between components. Lines convey the fluid and also dissipate heat. There
are various kinds of lines in a hydraulic system.

62
 CHAPTER FIVE

RESULTS AND DISCUSSION

From the above design calculations and estimated values the results calculated as well as the assumed
values for the main components are summarized in tabular form below.

Table 4:-detailed specifications and summary of the stone remover

No Name of parts Selected material type Parameter Dimension
1 Digging blade Steel ASTM A148-65 Width 1.15m
quenched and tempered Thickness, t 8mm
2 Chain conveyor Mild steel-MS320 Width 91cm
System and Length 105cm
cross rod
No of chain 38
links, k
Length of chain 2280mm
3 Sprockets Malleable cast iron BM Pitch 72mm
350 Tooth frank 55.65mm
radius, re
4 conveyor shaft Condition annealed Diameter 40mm
stainless steel 303
Length 1175mm
5 Universal joint malleable cast iron for Pin diameter(dp) 15mm
shaft and stainless-steel
AISI 303 for pin
6 Belt drive Natural rubber Length l=2m
Width w=90mm
Thickness t=8mm
7 Pulley Gray cast iron Width 112.5mm
Diameters Dl=150
Ds=100mm
8 Bevel gears Gray cast iron No. of teeth T1=10
T2=18
9 Stone collector Gray cast iron ASTM 30 Height 35cm
Length 120cm
10 Hydraulic Carbon steel rolled AISI Length of piston 45cm
cylinder 1035 rod
dumping Bore diameter 90mm
11 Frame Mild steel Height 710mm
Length 1420mm
Width 1180mm

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As the above calculations of design the components have designed based on calculating the
stresses on the main components as well as calculating the dimensions for some of the
components as desired.
Generally, the designed stone remover machine is mainly designed for answer the problems that
occur in agricultural fields due to many stones with in the farm. This stone remover machine can
be used to remove stones from 50 mm diameter of stones and above. From the design analysis it
can be concluded that the driving power of tractor is highly affects the stone removing process.
The designed stone remover can remove stones up to 2 hectare/day

Manufacturing processes of stone remover machine from farmland

The knowledge of manufacturing processes is of great importance for a design engineer. The
following are the various manufacturing processes used in stone remover machine.

1. Primary shaping processes: The processes used for the preliminary shaping of the
machine component are known as primary shaping processes. The common operations
used for this process are casting, forging, extruding, rolling, drawing, bending,
shearing, spinning, powder metal forming, squeezing, etc.
2. Machining processes. The processes used for giving final shape to the machine
component, according to planned dimensions are known as machining processes. The
common operations used for this process are turning, planning, shaping, drilling,
boring, reaming, sawing, broaching, milling, grinding, hobbing, etc.
3. Surface finishing processes. The processes used to provide a good surface finish for
the machine component are known as surface finishing processes.
4. Joining processes. The processes used for joining machine components are known
as joining processes. The common operations used for this process are welding,
riveting, soldering, brazing, screw fastening, pressing, sintering, etc.
Casting castings are obtained by re-melting of ingots in a cupola or some other foundry
furnace and then pouring this molten metal into metal or sand molds. The various
important casting processes that are used in the stone remover machine are the
following;
1. Sand mold casting. The casting produced by pouring molten metal in sand mold is
called sand mold casting. It is particularly used for parts of larger sizes.

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 2. Permanent mold casting. The casting produced by pouring molten metal in a
metallic mold is called permanent mold casting.

According the above the major components of the stone remover machine production
methodology is generalized below.

Frame: through bending, cutting, joining processes through welding and using mechanical
fasteners.

Conveyor system components: through sand and permanent mold casting processes, joining
through mechanical fasteners of bolts and nuts.

Digging blade: through cutting and drilling process, grinding

Conveyor shaft: through rolling,

Universal joint: machining through drilling as it has holes, joining process through pin
connection through the two sides

Pulley: through sand casting process, drilling process as it has hole.

Bevel gears: bevel gear mechanism is manufactured through horizontal milling machine

Parts assembly procedures

In assembling the stone remover machine components keep the following procedures
As the frame is holds most of the stone remover components the assembly is performed to the
frame.
1. First insert all the required bearings, and then insert the chain conveyor shaft and bevel gear
shaft across the frame through the one side of the frame.
2. Assemble all the sprockets with the chain drive shaft
3. Assemble the belt drive by inserting the smaller pulley along bevel gear shaft and similarly
insert the largest pulley also in the upper chain shaft.
4.attach the stone collector bin with the frame with in on both sides through the two pin hole so
does with the hydraulic stone cylinder rod at the center.
5. Assemble the universal joint with the power take off shaft coming from the tractor on one and
to the bevel gear shaft on the other; connect the three-point hitch to the backside of the tractor

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 CHAPTER SIX

CONCLUSION AND RECOMMENDATION

6.1. Conclusion
A stone remover machine from farm land with all dimensional constraints is designed. Likewise
the 3D model of the remover is designed in the SOLID WORKS 2016 software with isometric
view generated as well as 2D views. The machine so designed is of effective use to farmers to
overcome many of the problems faced by them during the field preparations. Comparing with
manual stone picking, only small number of human labors is required after the implementation of
the stone remover. It makes the process of land preparation faster. Hence it reduces the time
required to collect the same amount of stone manually which ultimately reduces the labor
required leading to reduction in the labor cost. This leads to economic development of farmers.
Hence the stone remover can be used by large number of farmers in areas which contains much
stones in the field as it is economical and affordable.
Additionally, it can also be modified for harvesting tuber crops like Tapioca, potato, radish,
turmeric it needs a large labor force for harvesting. Manual harvesting leads to lot damage of
tubers.
The stone remover is designed to work with in tractor through pulling action and as attached in
the backside. This particular innovation will help farmers to remove stone without the additional
labor involvement. By using this machine, a farmer can remove stones about 2-hectare farmland
in a day.

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6.2. Recommendation
Ethiopian agriculture is facing serious challenges as there are stones mixed with in the farmland
especially in Tigray. Therefore, the stones can be removed by fabricating this studied project
which increases the production capacity of crops, reduce damaging of cultivating tools, and
reduction of extra costs.
Besides the machine it is recommended to do the following:
 The machine could not be used in too muddy environments as they damage the
components of the machine; that is the components of the machine are subjected to
corrosion. And if the farmland is too muddy the machine doesn’t filter out the stones
from the soil.
 The machine should be only connected to 540 rpm PTO shaft otherwise failure of the
remover shaft will happen.

 The analysis of this study doesn’t consider thermal analysis for the components so that it
is recommended for the future to apply thermal analysis.

 The stone remover machine is analyzed based on the static analysis but the dynamic
behavior of the machine is not checked, it is recommending that other designer who want
to update this paper should have to consider dynamic behavior.
Future works
The designed stone remover machine from farmland was to remove stones further development in
future works will be in the way of providing an advanced conveyor provided with the stone collector
cabin and the machine designed is restricted to stones in the future through simple development in
the blade will be used for harvesting tubular fruits.

67
 References
1. stone removal and disposal practices in agriculture and farming. James, E Gage. 2014, field
clearing.
2. Alois Weigel, Burnstad, N. Dak. 2,763,975 United States Patent Office, Sept. 25, 1956 .
3. Jeannotte, Gerald and J, Jean. 5,027,906 united states patent office, Canada, 1990.
4. Design of agriculture stone picker. Syed, M. N., Wankhade, A. M., Kalandare, S.and
Kharwade. 2016, International Journal for Engineering Applications and Technology.
5. Gupta, R. S. Khurmi. and J. K. A Textbook of Machine Design. New Delhi, India : Eurasia
publishing house (PVT.) LTD., 2005.
6. Ch.R.Mischke, J.E Shigley-. standard handbook of machine design second edition. New
York : Mc Graw-Hill, 1996.
7. Johnston, F.Beer - Russel. Mechanics of materials Metric Edition ll. Singapore : Mc Graw-
Hill, 1992.
8. Rock separator with beveled tines and removable grates. Keigley, K. V. 2006, United States
Patent. No.7066275 B1.
9. Kepner, R. A., Bainer R., Barger E.L. Principles of Farm Machinery. New Delhi, India :
CBS Publishing Company, 2005.
10. Marshek, R. Juvinal - K. Fundamentals of Machine Components Design, Third Edition.
New York : John Wiley and Sons, 2000.
11. Robert L. Mott, RE. Machine elements in Mechanical design, fourth edition. Columbus :
Pearson Education. Inc.
12. Development of the Analytical Soil-Tool Interaction Model for the Earthmoving Operations.
Patel, Bhavesh P. 2011.
13. Modeling and Identification of Soil-tool Interaction in Automated Excavation. O. Luengo, S.
Singh, H. Cannon. 1998, pp. 03-08.
14. Design , Modeling and Analysis of conveyor system. Pradnyaratna A Meshram, Dr. A R
Sahu. 2016, International Journal of Research in Advent Technology, Vol.4, No.1 .
15. Earl R. Smith, W. Jordan Rd. 6,041,866 United States Patent, 2000.
16. Machine design Databook. s.l. : Mc Graw-Hill , 2004.

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 Appendices
Appendix 1: - Physical property of common metals (6)
Metals Modulus of Elasticity, Modulus of Poisson’s
E Rigidity, G Ratio,v
(Gpa) (GPa)
Cast Iron, 15 103 0.26
Steel, carbon 30 207 0.3
Steel, alloy 30 207 0.3
Steel, stainless 30 207 0.3
Appendix 2: - Typical Mechanical Properties of Gray Cast Iron (6)

ASTM Tensile Yield Torsional Compressive Brinell

Strength, Strength Shear (MPa) Strength (MPa) Hardne
Class
(MPa) (Mpa) ss, HB
30 214 178 276 752 210
40 293 208 393 965 235
60 431 244 610 1293 302
Appendix 3: - Mechanical Properties of Malleable Cast Iron (6)
Specification Number Grade Tensile Strength Yield Strength
(Mpa) (Mpa)
Ferrite: ASTM A47, A338; ANSI G 32510 345 224
48
ASTM A197 -- 276 207
Pearlite and Martensitic: ASTM 40010 414 276
A220; ANSI G48.2;MIL-I-11444B
45006 448 310
-- 619 483
Appendix 4:- Principal dimensions for radial ball bearings (5)
Bearing no Bore (mm) Outside diameter Width (mm)
207 35 72 17
307 80 21
407 100 25

69
Appendix 5:- Tensile properties of selected steels
Material Grade Ultimate strength(MPa) Yield strength(MPa)

Carbon and alloy steel AISI 1035 586 462

Stainless steel AISI 303 601 252

Mild steel MS 320 350

Appendix 6:- Characteristics of roller chains according to IS: 2403 — 1991 (5)
ISO Pitch Roller Width Transverse Breaking load (KN)
chain (p) diameter between inner Pitch (p1) minimum
number mm (d1) mm plates (b1)mm mm Simple Duplex Triplex
maximum maximum
05B 8.00 5.00 3.00 5.64 4.4 7.8 11.1
06B 9.525 6.35 5.72 10.24 8.9 16.9 24.9
10B 15.875 10.16 9.65 16.59 22.2 44.5 66.7
20B 31.75 19.05 19.56 36.45 64.5 129 193.5
28B 44.45 27.94 30.99 59.56 129 258 387
32B 50.80 29.21 30.99 68.55 169 338 507.10
40B 63.50 39.37 38.10 72.29 262.4 524.9 787.3
48B 76.20 48.26 45.72 91.21 400.3 800.7 1201
Appendix7:- Design dimensions of screw threads, bolts and nuts according to IS: 4218 (Part III)
1976 (Reaffirmed 1996) (5)

Designation Pitch(p) Major or Effective Minor or core Depth of Stress

mm nominal or pitch diameter (dc) thread(bolt) area
diameter nut diameter Mm mm mm2
and bolt nut and bolt Nut
(d) bolt(dp)
Mm mm
M10 1.5 10.000 9.026 8.160 8.876 0.920 58.3
M12 1.75 12.000 10.863 9.858 10.106 1.074 84.0
M14 2 14.000 12.701 11.546 11.835 1.227 115
M16 2 16.000 14.701 13.546 13.835 1.227 157
M18 2.5 18.000 16.376 14.933 15.294 1.534 192
M20 2.5 20.000 18.376 16.933 17.294 1.534 245

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Detailed part and Assembly drawings

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3D MODEL OF STONE REMOVER

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