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DESIGN AND ANALYSIS OF A CORN STALK WASTE

SHREDDER

A Design Output

Presented to the Faculty of Mechanical Engineering Department

College of Engineering, Architecture and Fine Arts

Batangas State University

Alangilan, Batangas City

In Partial Fulfillment

of the Requirements for the subject

ME 424 – Machine Design II

by:

Barcelon, Arhon G.

Brin, Nica G.

Cunag, Christian Jan T.

Perez, Gian Carlo L.

July 2022
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ABSTRACT

Unwanted trash generated as a result of agricultural activity is referred to as agricultural

waste. In most countries, agricultural waste is mishandled or abandoned since there is either no
adequate channel to transmit and use it or people are unaware of it. Corn stalk is composed of
leaves and stems that’s why it is considered as agricultural waste. This research work focused on
the design and analysis of corn stalk waste shredder that can be useful to the agricultural sector
in terms of proper disposal of waste and contribute to the economical aspect by using the
shredded corn stalks for ethanol production. This machine, specifically a corn stalk waste
shredder, consists of different parts and components such as frame, hopper, cutter, shaft, motor
and belt and pulleys. Material selection based on availability, durability, cost and ease of
fabrication were considered. The course of the process is affected by the geometric features of
the working elements (shape, size), the porosity of the shredded elements, and a number of
operating parameters. The machine components were calculated using theoretical calculation as
an application of the summary of the subject.
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TABLE OF CONTENTS

Abstract

Table of Contents

List of Figures

List of Tables

Body of the Proposal

I. Introduction
II. Objectives of the Design Project
III. Design Strategy
IV. Design Details
V. Design Verification
VI. Cost Analysis
VII. Conclusion

Reference

Appendix

Statement on the contribution of each team member

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LIST OF FIGURES

Figure No.

1 Cuttings Blades

2 Hopper

3 Shaft

4 Belt and Pulley

5 Motor
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LIST OF TABLES

Table No.

1 Cutter Specifications

2 Properties of ASTM A36 Mild Steel

3 AISI 1045 Steel Mechanical Properties

4 Mass Density of Various Belt Materials

5 Dimensions of Standard Flat belt (Power = 1.1 kW)

6 Dimensions of Standard pulley (Power = 1.1 kW)

7 Motor Specifications
8 Single Row Deep Groove Ball Bearing For Driver Shaft
9 Single Row Deep Groove Ball Bearing For Driven Shaft
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NOMENCLATURE

Power P (hp/kW) horsepower and/or

Kilowatts

Diameter D (mm) millimeter

Ultimate Stress σu (MPa) Mega Pascal

Bending Stress σb (MPa) Mega Pascal

Maximum Torque 𝑇𝑚𝑎𝑥 (N) Newtons

Density ⍴ 3
(𝑔/𝑐𝑚 ) Grams per cubic
centimeter

Speed N (rpm) revolutions per minute

Angle of Wrap θ (rad) Radians

Volume V 3
(c𝑚 ) cubic centimeter
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Introduction

The Philippines is mainly an agricultural country with a land area of 30 million hectares,
47 percent of which is agricultural. The total area devoted to agricultural crops is 13 million
hectares distributed among food grains, food crops and non-food crops. Among the crops grown,
rice, coconut, sugarcane, and corn are major contributors to biomass energy resources. Some
agricultural wastes are the side products during crop production, harvesting and processing. The
most common agricultural wastes in the Philippines are rice husk, coconut husk, coconut shell
and corn cobs/ stalks. It is estimated that corn cultivation began 7,000 years ago. Although
cultivating corn has always been a slow and painstaking process, technology is now profoundly
changing how we grow and harvest our food. A modern method exists today to assist growers in
producing healthy, superior corn yields. Local farmers now have a better method to grow and
deliver food to our tables due to modern plant breeding, which unites two particular parent plants
to create a new desired crop.

Corn stalks are made up of leaves and stems, which are cortex and pith. One of the
characteristics of corn stalks is the abundance of piths in the stem. The percentages of the leaf,
cortex and pith in the overall weight of the stalks are 40, 35, and 15 percent, respectively. Corn
stalks are nutritious both when they are young and when they are fully grown. The highest
concentration of crude protein is found in the leaves of mature corn stalks, followed by the
tassels and stalks, while the lowest concentration is found in the bracts. The nutritional value of
the different components is listed in the following sequence, from highest to lowest: leaves,
tassels, stalks, and bracts. According to weight, the bark makes up 64.8 percent of the stems
while the pith makes up 35.2%. Because straw has a very low protein content (often between 2
percent and 4 percent for the mass ratio) and a variable amino acid composition, it has poor
nutritional value when used directly as a ruminant feed. Corn stalk can be fed to rats and rabbits
as a source of protein after fermentation. The leaves are small, have a relatively large surface
area, a smooth waxy covering on the surface, have little mechanical strength, and quickly turn to
powder when crushed. They make up 40% of the weight of the corn stalk and 30% of the fibers.
Pith makes about 15% of the mass ratio and contains 20% of the fiber. Parenchyma and vascular
bundles are the main components of the pith. The corn stalk's ring measures 0.04 mm in
thickness, has a mass ratio of roughly 35 percent, and contains 50% fiber. In terms of mechanical
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strength, the rind is the strongest component of the corn stalk. It is a better raw material for
manufactured panels and paper because of its morphological fiber structure, which is similar to
that of cotton stalk and bagasse.

Considering this, the physical characteristics, chemical composition, and natural value of
corn stalk vary greatly, either within the same part of the stalk or between different parts.
Furthermore, the close cross-linking of three main substances which is cellulose, hemicellulose
and lignin in an unprocessed cornstalk provides it natural biomass recalcitrance. It is difficult to
directly use the stalk due to its complicated structural features. In order to achieve the combined
results of the application of primary components and the conversion of other components,
thereby improving the high-value usage of corn stalk, the condensed structure must be destroyed
or changed partially by pretreatments such as shredding.
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Objectives of the Design Project

The aim of this study is to design and analyze a Corn stalk waste shredding machine.

Specifically:

1. Design and analyze Corn stalk waste shredding machine considering the following

requirements:

1.1 machine components;

1.2 dimensions;

1.3 material properties

2. Determine the best type and specifications of machine components to be utilized including:

2.1 Electric Motor

2.2 Shaft

2.3 Cutting Blades

2.4 Transmission Drive

3. Conduct a performance evaluation taking into consideration of the following:

3.1 Operating speed of the shredding blades

3.2 Processing Rate

3.3 Shredding machine capacity

3.4 Maximum stress

3.5 Loading Capacity

4. Evaluate and compare the design options using standard materials.

5. Provide an analysis of the cost of each machine component.

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Design Strategy

The focus of this study is mainly to design and analyze corn stalk waste shredder.

However, lots of information regarding the topic was acquired as it was beneficial in building the

foundation of this study. It includes the data coming from books, manuals and other related

literature. Most of the background information used were from the internet for it is the broadest,

and easiest accessible source of information available. Furthermore, engineering design and

optimization, systematic planning and comprehensive analysis of data and observations were

involved in this design project since these are necessary in research analysis.

In analyzing the machine, specifically the corn stalk waste shredder, the proponents used

the concepts and data collected from various sources for its completion. Details, specifications,

and measurements of the materials were thoroughly analyzed and considered to develop

engineering layout and analysis. In addition, the operational cost and availability of the materials

used in this study were considered as well.

Material selection based on availability, durability, cost and ease of fabrication were

considered. The course of the process is affected by the geometric features of the working

elements (shape, size), the porosity of the shredded elements, and a number of operating

parameters. The susceptibility of corn stalks to shredding is related to a number of properties,

which include: low density, and high mechanical strength in relation to weight. Technical

indicators include data on the unit energy demand, and the possibility of cooperation of the

shredder with other technological equipment. Efficiency indicators are extremely useful for

comparison purposes.

A study on the mechanical properties of stalks in conjunction with such influence factors

is of practical significance in directing the design and improvement of stalk processing machines
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and technology. Study on corn stalk is now focused on cutting, compression and crushing

properties and a study on bending characteristics has been reported. The Physical and mechanical

characteristic parameters of corn stalks with 20-35 mm diameter and 110-165 mm in length were

tested: Through the data analysis shows that the maximum compression range is 97.5 ~ 243.5N,

and the compressive strength range is 0.38 ~ 1.18MPa, and yield strength range is 0 ~ 1.18MPa,

and elastic modulus range is 0.76 ~ 4.62MPa.

Equipment Description

The equipment is composed of a hopper, shredder blade, shaft and rotor. The Shredder

Design specification will give a clear idea for the designer to understand the required

specification to design the shredding machine the following specifications will be considered for

the design and analysis of the corn stalk waste shredder. In a study using maize straw, cereal

straw, and corn stalks as raw materials the power requirements for the machine to individually

grind plant materials were determined while using a single phase electric motor with 1.5 hp and

1400 rpm.

Equipment Design

The raw materials will be fed into the machine chamber through the hopper then coming

into contact with two shafts: the first one sucker roller and then into the cutter blade shaft. The

cutting blades will provide the shear force required to cut through corn stalks and the force

developed by the rotating shaft. The shredded materials will fall in the dumping stage. The

clearance between the rotating shafts and guides will vary depending on the size of the load.
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DESIGN PROCEDURE

A. Blades

The design and dimensions of the cutting blades utilized in the design and analysis of the

corn stalk wastes shredder will be based on previous research specifically from the study of the

International Journal of Innovative Science, Technology and Engineering (2015). Design

modifications will be taken into account in which will be best suited for the design.

Outer Diameter of the Cutter 150 mm

Inner Diameter of the Cutter 100 mm

Number of Teeth 6

Thickness of the Cutter 10 mm

Table #1. Cutter Specifications

Source: exportersindia.com
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B. Main Frame

A skeletal frame holding the main components of the shredder that is made up of steel

and joint by either bolts or welded together.

C. Hopper

The upper part of the machine and the unit where corn stalks will be fed manually to the

shredding chamber and will be designed as a wedge with converging end walls. This parameter

will directly quantify the number of corn stalks that can be fed to the shredding chamber

Volume of hopper (𝑉ℎ) = 1/3 (𝐴₁ + 𝐴₂ √𝐴₁ + 𝐴₂)ℎ

Where:
A₁= area of top base
A₂= area of bottom base
h= Height of hopper

The material chosen for the hopper and main frame will be ASTM A36 mild steel. Mild

steel is chosen because of its strength, toughness, and availability. This type of steel is also used

for automotive, construction and heavy equipment components.

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Table #2. Properties of ASTM A36 Mild Steel

https://www.metalsupermarkets.com/grade-guide-a36-steel/

Source: patriot-products-inc.com

D. Shaft

The shaft will deliver power under various loading conditions and the shaft diameter will

determine its rigidity and strength. Commonly made of Carbon Steel and Alloy Steels. For the

Design of the Shaft assuming that the length of the shaft will be 20 times of its diameter.

𝑇𝑚𝑎𝑥 = π⁄16 τ(𝑑)^3

Where:
𝑇𝑚𝑎𝑥= Maximum Torque
τ = Shear stress
𝑑 = diameter of the shaft

Source: Indiamart.com
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Table #3. AISI 1045 Steel Mechanical Properties

Density 7.87 𝑔/𝑐𝑚
3

Hardness, Brinell 163

Ultimate Tensile Strength 585 MPa

Yield Strength 450MPa

Elongation at Break 12%

Reduction of Area 35%

Modulus of Elasticity 206 GPa

Bulk Modulus 163 GPa

Poisson’s Ratio 0.29

Shear Modulus 80GPa

E. Belt and Pulley

Belt. Materials are frequently fed into the shredder using a flat, inclined belt.
Depending on the operation, a number of techniques can be used to load the material onto
the belt. Front-end loaders, forklifts, grapple tools, and drop-bottom containers are some
examples of the material handling tools that may be used to complete this operation. The
Cornstalk Waste shredder will be utilizing Rubber as the V-belt material.

Table #4. Mass Density of Various Belt Materials

Source:www.engineersgallery.com
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Pulley. A wheel characterized as a pulley has a flexible rope, cord, cable, chain,
or belt attached to its rim. To convey power and motion, pulleys can be used singly or in
conjunction with other devices. Sheaves are the name for pulleys with grooved edges.
Belt drives distribute power between shafts by having pulleys run over endless belts that
are fastened to the pulley containers at the axles of the shafts.

Source: Indiamart.com

Driver and Driven Pulley

𝑁₂/𝑁₁ = 𝑑₁/𝑑₂

Where:
𝑁₂ = 𝑆𝑝𝑒𝑒𝑑 𝑜𝑓 𝑡ℎ𝑒 𝐹𝑜𝑙𝑙𝑜𝑤𝑒𝑟
𝑁₁ = 𝑆𝑝𝑒𝑒𝑑 𝑜𝑓 𝑡ℎ𝑒 𝐷𝑟𝑖𝑣𝑒𝑟
𝑑₁ = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝐷𝑟𝑖𝑣𝑒𝑟
𝑑₂ = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑑𝑟𝑖𝑣𝑒𝑛 𝑝𝑢𝑙𝑙𝑒𝑦

Length of the Belt is one of the essential parameters that need to be considered in the
design of the shredding machine.

2
𝐿 = π/2(𝑑₂ + 𝑑1) + 2𝐶 + (𝑑₂ − 𝑑1) /4𝐶
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Where,

L = length of the belt

d₁ = diameter of driver shaft

d₂ = diameter of driven shaft

C = center distance between two pulleys

For the angle of wrap or angle of contact;

Equation for the driver shaft

−1 2
θ₁ = 180 − 2𝑠𝑖𝑛 (𝑑₂ − 𝑑₁) /4𝐶

Equation for the driven shaft

−1 2
θ₂ = 180 + 2𝑠𝑖𝑛 (𝑑₂ − 𝑑₁) /4𝐶

Face width

𝐵 = (𝑛 − 1)𝑒 + 2𝑓

Mass of Belt per length

𝑀𝑏/𝐿 = 𝐴 × ⍴

Where:

𝑀𝑏/𝐿 = 𝑀𝑎𝑠𝑠 𝑏𝑒𝑙𝑡 𝑝𝑒𝑟 𝑙𝑒𝑛𝑔𝑡ℎ

𝐴 = 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑏𝑒𝑙𝑡 (𝑏𝑡)
3
⍴ = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑟𝑢𝑏𝑏𝑒𝑟 𝑏𝑒𝑙𝑡 = 1140 𝑘𝑔/𝑚

Centrifugal Tension

2
𝑇𝑐 = 𝑀𝑏/𝐿✕𝑣
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Maximum Tension

𝑇 = 𝜎𝐴

Tight side and Slack Side Tension

𝑇₁ = 𝑇 − 𝑇𝑐

2. 3 𝑙𝑜𝑔 (𝑇₁/𝑇₂) = μθ(1/𝑠𝑖𝑛β)

Where:

𝑇₁ = 𝑇𝑖𝑔ℎ𝑡 𝑠𝑖𝑑𝑒 𝑇𝑒𝑛𝑠𝑖𝑜𝑛

𝑇₂ = 𝑆𝑙𝑎𝑐𝑘 𝑠𝑖𝑑𝑒 𝑇𝑒𝑛𝑠𝑖𝑜𝑛
𝑇𝑐 = 𝐶𝑒𝑛𝑡𝑟𝑖𝑓𝑢𝑔𝑎𝑙 𝑇𝑒𝑛𝑠𝑖𝑜𝑛
μ = 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛
θ= 𝑎𝑛𝑔𝑙𝑒 𝑜𝑓 𝑤𝑟𝑎𝑝
β= 𝑑𝑒𝑒𝑝 𝑔𝑟𝑜𝑜𝑣𝑒 𝑎𝑛𝑔𝑙𝑒

Power Transmitted

𝑃 = (𝑇₁ − 𝑇₂)𝑣

Number of Belts

𝑁𝑏 = 𝑑𝑒𝑠𝑖𝑔𝑛 𝐻𝑜𝑟𝑠𝑒𝑝𝑜𝑤𝑒𝑟 (𝑠𝑒𝑟𝑣𝑖𝑐𝑒 𝑓𝑎𝑐𝑡𝑜𝑟)/ 𝑆𝑡𝑎𝑛𝑑𝑎𝑟𝑑 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑠𝑠𝑖𝑜𝑛

For Tension 1 & 2,

2
𝑃 = 𝐹𝑛𝑒𝑡 𝑥 (𝑉) × (1𝑚𝑖𝑛/60𝑠𝑒𝑐)

=P= Fnet x (𝜋D₂N₂) (1min/60sec)

=P= (T₁-T₂) x (𝜋D₂N₂) (1min/60sec)

𝑃𝑜𝑤𝑒𝑟 = 2π𝑇𝑁/60
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Where,

P = Power output of the shaft

T = Torque obtained from the shaft

Fnet = Total net force

N = Rotational speed

To calculate for the output power use the equation

Po = 2πToNo /60

where:

Po = output power

To = output torque

No = rotational speed

For the input power

Consider the equation 0.96Pi = Po

Where:

Pi = input power

Po = output power

Belt Tension Ratio is to be computed. This parameter is very important in calculating the
Net Force that will be using to solve Power transmitted by the belt;

𝑓θ
𝑇₁/𝑇₂ = 𝑒
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After determining the formula, derivation of the equation is the next requirement. Hence,
using Net Force Formula to acquire Tight Side is strongly recommended.

𝐹𝑛𝑒𝑡 = 𝑇₁ − 𝑇₂

𝑇₁ = 𝐹𝑛𝑒𝑡 + 𝑇₂

Where,

T₁ = tension at the tight side of the belt

T₂ = tension at the slack side of the belt

f = coefficient of friction

Motor

Electrical motors are frequently employed in machinery, providing the necessary

driving power. However, because they are utilized in such large quantities and when they reach

the end of their useful life, recycling them is difficult. Strong axles and several thick components

within the motor make recycling difficult. Shredwell provides machines that can shred motors

and rotors directly with a high throughput. The effectiveness of recycling motors is greatly

increased by this equipment, which also makes it possible to recycle motors and rotors.

Figure #. Single Phase Electric Motor

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https://compressedaircentre.com/

Table #7. Motor Specifications

Model 3HP220V2800

Type SIngle Phase

Power 3hp / 2.24 kW

Voltage 220 V

Speed 2800 rpm

Efficiency 96%

Design Details

The design of corn stalk waste shredder will be considering some factors including the

efficiency of the machine,availability and durability of the materials, ease to operate, and the cost

of fabrication.

A. Design of Cutting Blades

Figure #1. Cutting Blades

Cutter Specifications

Cutting Blade Width: 10 mm

Outer Diameter: 150 mm

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Inner Diameter: 100 mm

Number of Teeth: 6

Width of the Chamber : 500 mm

● Number of Cutting Blade : n = Shaft length / cutting blade width

N = 500 mm / 10 mm

N = 50 mm

The number of cutting blades is 50, and we are going to divide it by two by

having a dual shaft. Aside from that, we need to provide allowance for both sides so our total

number of cutting blades is 24.

● To calculate the Torque developed for each blade using Force required to shred corn

stalks 3220 N (Azadbakht, 2014):

T = Ft x R

T = 3220N × 0.150m

T = 241.5 Nm per blades

● Therefore, the torque developed in each shaft is:

T = 241.5 Nm x 24

T = 5796 Nm

Total =11592 Nm

● Cutting edge area : A = LW; (20mm)(10mm) = 200mm2

S = F/A
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Where; S = shear strength of corn stalks = 0.87 MPa (bioresources.cnr)

0.87 MPa = F / 200 mm²

Force = 174 N

● Torque: Tblade = (1.5m)(174 N)

Tblade = 261 Nm

Figure #2. Hopper

B. Design of Hopper

Volume of hopper (𝑉ℎ) = 1/3 (𝐴₁ + 𝐴₂ √𝐴₁ + 𝐴₂)ℎ

where:

A₁= area of top base = 50 cm x 40 cm = 2000cm²

A₂= area of bottom base = 50 cm x 20 cm = 1000cm²

h= Height of hopper = 24 cm
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𝑉ℎ = ⅓[ ( 2000 𝑐𝑚² + 1000 𝑐𝑚²)(√2000 𝑐𝑚² + 1000 𝑐𝑚²)]24𝑐𝑚

𝑉ℎ = 1314. 534138 𝑐𝑚³

𝑉ℎ = 1315 𝑐𝑚³

Volume of Stalks in the shredder

2
Vs= π𝑟 ℎ

2
𝑟 =average of stalks in cm =(2 𝑐𝑚 + 3. 5 𝑐𝑚)/2

h= average length of stalks in cm =(11 𝑐𝑚 + 16. 5 𝑐𝑚)/2

2
Vs= π(2. 75) (13. 75)

Vs= 326.6765486 cm³

𝑁𝑜. 𝑜𝑓 𝑠𝑡𝑎𝑙𝑘𝑠 𝑡ℎ𝑎𝑡 𝑐𝑎𝑛 𝑓𝑖𝑙𝑙 𝑖𝑛 𝑡ℎ𝑒 ℎ𝑜𝑝𝑝𝑒𝑟 = 𝑉ℎ/ 𝑉𝑠

= 1315 𝑐𝑚^3/ 327 𝑐𝑚³

= 4.021406728

= 4 stalks at a time
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Figure #3. Shaft

C. Design for Cutting Blade Shaft

The shaft is a rotating machine component that transfers power from one component to

another, as was indicated in the introduction of this work. Power is transferred from one

component to another by shafts, which are connected to pulleys, gears, and other parts. These

parts, and the forces imposed on them, cause the shaft to flex. Or, to put it another way, we may

say that a shaft is used to transport both torque and bending moment. The various components

are mounted to the shaft using keys or splines.

A transmission shaft is the kind of shaft that will be used to attach the cutting blades; it

transfers and absorbs power between the power source and the machine part. Since the machine's

primary function is shredding, the shredding shaft is also subject to varying loads.

Cutting blade shaft with key

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The shaft design that is being offered falls under the category of a solid shaft and serves

as a holder for the cutting blades inside the shredding chamber. The length of the shaft in this

design is fixed at 500 mm or 50cm, with 50 counts of cutting blades

For the Cutting blade

3
Volume, V = 128.13 𝑐𝑚

3
Density, ρ = 0. 02793 𝑙𝑏/𝑖𝑛

𝑊𝑏𝑙𝑎𝑑𝑒 = 𝑉 𝑥 ρ 𝑥 𝑔

3 3 2
𝑊𝑏𝑙𝑎𝑑𝑒 = 128. 13 𝑐𝑚 𝑥0. 02793 𝑙𝑏/𝑖𝑛 𝑥 9. 81 𝑚/𝑠

𝑊𝑏𝑙𝑎𝑑𝑒= [(

3 3 3 2 2
128. 13 𝑐𝑚 )(1𝑚/100𝑐𝑚) ] 𝑥 [(0. 02793 𝑙𝑏/𝑖𝑛 )(1𝑘𝑔/2. 21𝑙𝑏)(1𝑖𝑛/0. 0254𝑚) 𝑥 9. 81 𝑚/𝑠

𝑊𝑏𝑙𝑎𝑑𝑒 = 0. 2462243855 N

Considering the number of blades,

𝑊𝑏𝑙𝑎𝑑𝑒 = 0. 2462243855N x 50

𝑊𝑏𝑙𝑎𝑑𝑒 = 12.31121928 N

For the Spacers

3
Volume, V =65.4 𝑐𝑚

3
Density, ρ = 8. 0𝑔/𝑐𝑚

𝑊𝑠𝑝𝑎𝑐𝑒𝑟 = 𝑉 𝑥 ρ 𝑥 𝑔

3 3 1𝑘𝑔 2
𝑊𝑠𝑝𝑎𝑐𝑒𝑟 = 65. 4𝑐𝑚 𝑥 8. 0 𝑔/𝑐𝑚 𝑥 1000𝑔
𝑥 9. 81 𝑚/𝑠
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3 3 3 1𝑘𝑔 3 2
𝑊𝑠𝑝𝑎𝑐𝑒𝑟 = [(65. 4𝑐𝑚 )(1𝑚/100𝑐𝑚) 𝑥[ (8. 0 𝑔/𝑐𝑚 )( 10000𝑔 )(100𝑐𝑚/1𝑚) ]𝑥( 9. 81 𝑚/𝑠 )

𝑊𝑠𝑝𝑎𝑐𝑒𝑟 = 0. 5132592 N

Considering the number of spacers,

𝑊𝑠𝑝𝑎𝑐𝑒𝑟 = 0. 5132592N x 50

𝑊𝑠𝑝𝑎𝑐𝑒𝑟 = 25.66296 N

Thus, the total weight, W = 𝑊𝑏𝑙𝑎𝑑𝑒 + 𝑊

𝑠𝑝𝑎𝑐𝑒𝑟

W = 12. 31121928 𝑁 + 25. 66296𝑁

W = 37.97417928N

Using the equation to get the maximum bending moment,

𝑊𝑥𝐿
M= 4

37.97417928𝑁 𝑥 50𝑐𝑚
M= 4

M = 474.67721N-cm x 1m/100cm

M = 4.74677241 Nm

Using the equation of shear stress in solid shafts,

2 2
𝑇𝑒 = (𝑘𝑚 𝑀 ) + (𝑘𝑡 𝑇 )

Given the constants and the spinning shaft characteristic, the values for km and kt are as

follows. This number is from Table 14.2 Recommended Values for km and kt and only applies to

suddenly applied loads with small shocks. .

2 2
𝑇𝑒 = [ (2. 0)(4. 74677241 𝑁𝑚) ] + [(2. 0) (15𝑁𝑚 ) ]

𝑇𝑒 = 22.25002689 Nm
`

For the Equivalent Bending Moment, Me

2 2
Me = ½ (𝑘𝑚 𝑥 M + 𝑀 + 𝑇 )

Me = ½[(2.0)( 4.74677241Nm) + (22.25002689 Nm)]

Me =15.87178586 Nm

Considering the values of maximum permissible working stress for transmission shafts

stated in the Textbook of Machine Design by RS Khurmi and JK Gupta, the maximum or

ultimate working stress for shafts is 84 MPa with maximum shear stress of 42 MPa.

Substituting the values,

π 3
𝑇𝑒 = 16
𝑥 τ 𝑚𝑎𝑥 𝑥 𝑑

π σ𝑦 𝑥 0.5 3
𝑇𝑒 = 16
𝑥 𝑓𝑠
𝑥𝑑

Computing for the diameter,

𝑇𝑒
d = 3√ π σ𝑦 𝑥 0.5
( 16
𝑥 𝑓𝑠
)

22.25002689 𝑁𝑚
d = 3√ π
6
275𝑥10 𝑥 0.5
( 16 𝑥 8
)

d = 0.01875121066mm x 1000mm/1m

d =18.75121066mm

Ultimate stress for steel,σu = 550 MPa

Yield stress for steel,σy = 275 MPa

`

D. Design for the Motor and Its Specification

200 𝑘𝑔 𝑜𝑓 𝑐𝑜𝑟𝑛 𝑠𝑡𝑎𝑙𝑘𝑠

● Desired output = 1 ℎ𝑟

1𝑘𝑔
Output per revolution = 𝑟𝑒𝑣

𝑑𝑒𝑠𝑖𝑟𝑒𝑑 𝑜𝑢𝑡𝑝𝑢𝑡
N= 𝑜𝑢𝑡𝑝𝑢𝑡 𝑝𝑒𝑟 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛

200𝑘𝑔/ℎ𝑟 1 ℎ𝑟
N= 1𝑘𝑔/𝑟𝑒𝑣
x ( 60𝑚𝑖𝑛 )

● The desired speed for the shredder blade,

N = 3.33 rpm ≅ 3.5 rpm

● The total torque developed is 5796 Nm

● The rotational speed that will be used by the shaft is 3.5 rpm

2𝝅𝑇𝑁
● Power required to shred, 𝑃= 60

2𝝅(5796𝑁𝑚)(3.5 𝑟𝑒𝑣/𝑚𝑖𝑛)
𝑃= 60

P = 2124.344952 W

● Motor power efficiency is 96%,

𝑃𝑜 = 0. 96𝑃𝑖

𝑃𝑖 = 𝑃𝑜/0. 96 = 2124. 344952/ 0. 96

1ℎ𝑝
𝑃𝑖 = 2039. 371159 𝑊 ( 745.699872 𝑊 )

Pi = 2.734841772 hp ≈ 3 hp
`

E. Design of Gear

● Distance between the 2 cutting blades shaft’s axes is 225 mm

Dp = Distance between the 2 shafts

Dp = 225 mm

Therefore, Dp = 225 mm

Module, m = 5.5 mm

𝐷𝑝
Tn= No. of teeth = 𝑚

225 𝑚𝑚
T= 5.5 𝑚𝑚

Therefore, T = 41

π𝐷𝑝
Given the equation for Circular pitch, 𝑝𝑐 = 𝑇

π (225𝑚𝑚)
𝑝𝑐 = 41

Therefore, 𝑝𝑐 = 5. 4878π = 17.24044748921 mm

𝑇
The diametral pitch, 𝑝𝑑 = 𝐷𝑝

41
𝑝𝑑 = 225𝑚𝑚

𝑝𝑑 = 0.18

To determine the Face width, b:

𝑊𝑇
b= (σ)(π)(𝑚)(𝑦)

𝑃
Where, 𝑊𝑇 = 𝑣
(Cs)
`

2𝝅𝑇𝑁
Given the equation for power, P= 60

𝝅𝑚𝑇𝑛𝑁 𝑝𝑐𝑇𝑛𝑁
Given the equation for Pitch Line Velocity, v = 60
= 60

Substituting the values,

2𝝅 (3336 𝑁𝑚)(5 𝑟𝑒𝑣/𝑚𝑖𝑛)

P= 60 𝑠𝑒𝑐/𝑚𝑖𝑛

P = 1746.72551539592 W

𝝅(0.0055𝑚)(5 𝑟𝑒𝑣/𝑚𝑖𝑛)(41)
For the pitch line velocity, v= 60 𝑠𝑒𝑐/𝑚𝑖𝑛

v = 0.05903576195 m /s

For the service factor, Cs, according to chapters 13 & 14 of Shigley's Mechanical

Engineering Design 8th edition textbook, the service factor for this type of gear, in which the

type of load is applied for steady with an operation of 8-10 hours per day, is 1.00.

1746.72551539592 𝑊
Therefore, 𝑊𝑇 = 0.05903576195 𝑚 /𝑠
(1)

𝑊𝑇 = 29587.58314855868 N

Solve for the value of y in terms of the number of teeth which is be expressed as

0.912 ◦
y = 0.154 - 𝑇𝑛
, for 20 full depth involute system

0.912
y = 0.154 - 41

y = 0.13175609756

Solve for the bending stress, σ,

σ = σ𝑜 x Cv

3
Where, Cv = 3+𝑣

2 3
Therefore, σ = 115 N/𝑚𝑚 ( 3+0.05903576195 𝑚/𝑠
)
`

σ = 112.78063639899 MPa

𝑊𝑇
Now solve for the face width, b= (σ)(π)(𝑚)(𝑦)

29587.58314855868 𝑁
b= (112.78063639899 𝑀𝑃𝑎)(π)(5.5𝑚𝑚)(0.13175609756)

b = 115.23692611961 mm = 116mm T = 41 Dp = 225 mm

F. Design for the Shaft (Driver and Driven)

Driver Shaft

Design Parameters:

Speed of the driver shaft = 2800 rpm

Power of the motor = 2124. 344952 𝑊

𝑇1 = 260.3607816 N

𝑇2 = 107.7698431N

Tc = 18.22721677 N

Assume length = 0.2 m

Solve for Torque in the driver shaft,

2𝝅𝑇𝑁
𝑃= 60

2𝝅𝑇(2800 𝑟𝑝𝑚)
2124. 344952 W = 60

T = 7.24499999Nm

Solve for bending moment on the shaft due to tension on the belt,

M = (𝑇1+ 𝑇2 + 2Tc) L

= (260.3607816 N + 107.7698431 N) + 2(18.22721677 N)) 0.2m

M = 375.4125114 Nm
`

Solve for equivalent twisting moment

2 2
Te = 𝑀 + 𝑇

2 2
= (375. 4125114 𝑁𝑚) + (7. 24499999𝑁𝑚)

Te = 375.491413 Nm

Solve for equivalent bending moment,

Me = ½ (M +Te)

= ½ (375. 4125114 𝑁𝑚 + 375.491413 Nm)

Me = 375.4519622 Nm

Let τ and σb be the maximum allowable permissible stress for twisting and bending,

τ = 44 MPa

σb = 75 MPa

Solve for diameter of the shaft of the driver pulley,

π 3
Te = 16
𝑥τ 𝑥𝐷

π 6 3
375.491413 Nm = 16
[ ( 44x10 )( 𝐷 )]

D = 0.0351592132 m ≅ 35 to 38 mm

Design of the Key

Standard Key Dimensions indicated in BS 4235-1 : 1972 for nominal shaft

diameter of 38 mm

Width = 12 mm

Thickness = 8mm
`

Driven Shaft

Design Parameters:

Speed of the driven shaft = 1400 rpm

Power of the motor = 2124. 344952 𝑊

𝑇1 = 260.3607816 N

𝑇2 = 107.7698431N

Tc = 18.22721677 N

Assume length = 0.2 m

Solve for Torque developed in the driven shaft,

2𝝅𝑇𝑁
𝑃= 60

2𝝅𝑇(1400 𝑟𝑝𝑚)
2124. 344952 𝑊 = 60

T = 14.49999999 Nm

Solve for bending moment on the shaft due to tension on the belt,

M = (𝑇1+ 𝑇2 + 2Tc) L

= (260.3607816 N + 107.7698431N + 2( 18.22721677 N)) 0.2m

M =80.91701165 Nm

Solve for equivalent twisting moment

2 2
Te = 𝑀 + 𝑇

2 2
= (14. 49999999 ) + (80. 91701165𝑁𝑚)

Te = 82.20591689 Nm
`

Solve for equivalent bending moment,

Me = ½ (M +Te)

= ½ (80.91701165 Nm + 82.20591689 Nm)

Me = 81.56146427 Nm

Let τ and σb be the maximum allowable permissible stress for twisting and bending,

τ = 44 MPa

σb = 75 MPa

Solve for diameter of the shaft of the driven pulley,

π 3
Te = 16
𝑥τ 𝑥𝐷

π 6 3
82.20591689 Nm = 16
x 44x10 x 𝐷

D = 0.0211904495 m ≅ 22 mm

Design of the Key

Standard Key Dimensions indicated in BS 4235-1 : 1972 for nominal shaft

diameter of 22 mm

Width = 8 mm

Thickness = 7 mm
`

G. Design for the Transmission Drive (Belt and Pulley)

● Design Parameters:

Smaller pulley: 𝑑1= 100mm

Larger pulley: 𝑑2 = 200mm

Speed of the motor (driver): 𝑁1 = 2800 rpm

Center distance of the two pulleys: C = 250mm

f = 0.30

Motor Power = 3 hp

● Solving for speed of the driven (𝑁2) using velocity Ratio:

𝑁2 / 𝑁1 = 𝐷1/ 𝐷2

𝑁2= (2800 rpm * 100 mm)

200

𝑁2 = 1400 rpm

● Calculating the length of the belt:

2
π (𝑑2−𝑑1)
𝐿 = 2
(𝑑2 + 𝑑1) + 2𝐶 + 4𝐶

2
π (200𝑚𝑚−100𝑚𝑚)
L= 2
(200𝑚𝑚 + 100𝑚𝑚) + 2(250𝑚𝑚) + 4(250𝑚𝑚)

L = 981.238898 mm or approximately 0.98 - 1 m

● Solving for the value of the angle of wrap for the smaller pulley

−1 𝑟2−𝑟1 −1 100𝑚𝑚−50𝑚𝑚
θ𝑑𝑟𝑖𝑣𝑖𝑛𝑔 = 180 − 2 𝑠𝑖𝑛 ( 𝐶 ) = 180 − 2 𝑠𝑖𝑛 ( 250𝑚𝑚 )

= 168.463041 (π/180)
`

θ𝑑𝑟𝑖𝑣𝑖𝑛𝑔 = 2.940234733 rad

● Solving for the value of the angle of wrap for the larger pulley

−1 𝑟2−𝑟1 −1 100𝑚𝑚−50𝑚𝑚
θ𝑑𝑟𝑖𝑣𝑒𝑛 = 180 + 2 𝑠𝑖𝑛 ( 𝐶 ) = 180 + 2 𝑠𝑖𝑛 ( 250𝑚𝑚 )

= 191.536959 (π/180)

θ𝑑𝑟𝑖𝑣𝑒𝑛 = 3.3429505742 rad

● To determine the two tensions of the belt, two equations will be utilized using this

formula,

𝑇1 𝑓θ
𝑇2
=𝑒 .

● The value for f is 0.30. The equation is represented using the smaller value of the angle of

wrap.

𝑇1 (0.30)(2.9402347336 𝑟𝑎𝑑)
𝑇2
=𝑒

𝑇1
𝑇2
= 2. 415896452

● Interpreting the relationship as the value of 𝑇1,

𝑇1 = 2. 415896452 𝑇2

● Power transmitted is achieved by the formula, 𝑃 = 𝐹𝑛𝑒𝑡𝑣, where:

𝐹𝑛𝑒𝑡 = 𝑇1 − 𝑇2

● Solving for velocity,

π𝑑1𝑁1 π(0.100𝑚)(2800 𝑟𝑒𝑣/𝑚𝑖𝑛)

𝑉 = 60
= 60𝑠/𝑚𝑖𝑛

V = 14.66076572 m/s
`

● Solve for 𝑇2 by inserting the equation taken from the tension ratio,

745.7 𝑊𝑎𝑡𝑡𝑠
(3ℎ𝑝 × 1ℎ𝑝
) = (2. 415896452 𝑇2− 𝑇2)× (14. 66076572 𝑚/𝑠)

Therefore, 𝑇2 =107.7698431 N

● Solve for 𝑇1 from the equation taken from tension ratio,

𝑇1 = 2. 415896452 (107. 7698431 𝑁)

Therefore, 𝑇1 = 260.3607816 N

● Solving for width of the belt,

Design parameters

Density of rubber = 1522 kg/m^3

Thickness of the belt = 0.005m

Allowable stress for belt = 5 MPa

● We know that the equation for mass = volume x density

Where, volume = Area * length(l)

Area = width(b) * thickness(t)

● Therefore, m = btl x density

● Substituting values to solve for m,

m = b (0.005m)(1m) (1522 kg/m³)

m = 7.61(b) kg/m

● Calculating the velocity of the motor pulley:

π(0.100𝑚)(2800 𝑟𝑒𝑣/𝑚𝑖𝑛)
𝑉 = 60𝑠/𝑚𝑖𝑛

V = 14.66076572 m/s
`

● Since it has a large velocity we need to consider the centrifugal tension,

2
Tc = 7.61 (b) kg/m ✕ ( 14. 66076572 𝑚/𝑠)

2
Tc = 1635.678572 (b) kg/𝑠

● From the formula of the maximum tension,

Where, T = 𝑇1 + Tc

Substituting values,

2 6
260.3607816 N + 1635.678572 (b) kg/𝑠 = 5 𝑥 10 𝑃𝑎 x (b)(0.005m)

b = 0.0111435199 m or approximately 11.1435199 mm = 12 mm

● Solve for centrifugal tension,

2
Tc = 1635.678572 (0.0111435199) kg/𝑠

Tc = 18.22721677 N

● Solve for maximum tension,

Tmax = 260.3607816 N +18.22721677 N

Tmax =278.5879984 N
`

H. Design for the Gearbox

Figure #4. Gearbox

Design Parameters:

Required speed to shred = 3.5 rpm

Speed from the driven shaft = 1400 rpm

To select a specific gearbox, we need to know the ratio between the output speed to the

input speed in the gearbox.

1400 rpm : 3.5 rpm = 400:1 Gearbox

Specification of the selected gearbox

Ratio: 400:1

Output Shaft Diameter: 6mm

Efficiency @ 1000 RPM: 0.85

Type: In-Line

Output Torque @ 3000 RPM: 0.56 Nm

`

Weight: 140g

Material: Delrin/Aluminum/Steel

Box Length: 50mm

Input Keyway Height: 2mm

Max Input RPM: 4,000

Housing Material: Delrin/Aluminum

Output Key Width: 2mm

Input Key Length: 14mm

Input Shaft Length: 20mm

Output Shaft Length: 20mm

Box Diameter: 50mm

Input Key Width: 2mm

Shaft Output Type: In-Line

Use Output Key: KK2-14

Output Key Height: 2mm

Use Input Key: KK2-14

Output Key Length: 14mm

Input Shaft Diameter: 6mm

I.Design for the Bearings

The Design of the Corn stalk shredding machine will utilize a bearing attachment for

smoother rotation and reduce friction between the rotating shaft and supports it will also prevent
`

unnecessary movement and contact with other machine members and also prevents damage of

the rotating shaft.

Table #8. Single Row Deep Groove Ball Bearing For Driver Shaft

https://koyo.jtekt.co.jp/en/support/catalog-download/uploads/catb2001e_b.pdf

Table #9. Single Row Deep Groove Ball Bearing For Driven Shaft
`

https://koyo.jtekt.co.jp/en/support/catalog-download/uploads/catb2001e_b.pdf
`

J.Design for the Frame

Figure #. Frame of the Corn Stalk Waste Shredder

Frame is a rigid structure or a foundation that gives shape and support to the machine. It

serves as the outline of the machine where other components are placed for it to function well.

The material used for the frame is alloy steel so it can handle the weights of the components

being carried by it. The performance requirements of the alloy must be completely thought about

while designing the alloy composition. A certain amount of hardenability, high hardness, and

robustness are required during design. The wear resistance of bainite is better than that of

martensite at the same hardness because it has a lower overall internal stress than martensite.
`

Design Assembly

Figure #. Isometric View of the Corn Stalk Waste Shredder

`

Figure #. Right Side View of the Shredder

Figure #. Front View of the Corn Stalk Waste Shredder

`

Figure #. Top View of the Corn Stalk Waste Shredder

Figure #. Shredder Shaft Assembly

`

Figure #. Belt and Pulley Assembly

Design Verification

This section displays the outcomes of the theoretical computation and the Solidworks

simulation. These simulation and theoretical results will be utilized to assess or analyze the

design of the shredding machine.

A. Solidworks Simulation

Stress analysis is the study of stresses and strains that occur when forces are applied to

materials and structures. Materials may deform or fracture as a result of stress. The goal of stress

analysis is to determine how much stress results in deformation in a particular material. Using

the application Solidworks and its simulation feature, the researcher easily provides the result of

the stress analysis in the components of Cornstalk Waste Shredder.

`

1. Shredder Blade

Shown in the table below are the mechanical properties of the cutting blade which is used

and considered for the simulation of this machine component.

Mass = 1.25897 kg

Volume = 0.000160379 m^3

Density = 7,850 kg/m^3

Weight = 12.3379 N
Table #. Properties of the Cutting blade

Stress Analysis

Using Von Mises Stress Analysis in Solidworks, the researcher started analyzing the

stress by applying the material used in the cutting blade. Next, force is applied to the area of

contact between the blade and aluminum can which is 3,220 N.. To create a more accurate result,

mesh is applied to the machine part. Based on the result, it shows that the maximum stress

occurring to the area that force applied is 45.33 MPa.

`

Figure #. Stress Analysis of the Cutting Blade

Deformation Analysis

Deformation occurs when there is a change in shape in the object where the force is

applied. Based on the result of analysis for displacement using URES in solidworks simulation,

the red part indicates the location where the maximum amount of displacement occurs. The

displacement is recorded as 0.01864 mm which is small considering the size of the cutter blade.
`

Figure #. Deformation Analysis of Cutting Blade

Strain Analysis

Strain refers to a measure of the amount of deformation that takes place on an object due

to force. Based on the result of the ESTRN in solidworks simulation, the maximum strain located

area that has the maximum stress is recorded as 0.0001845 which cannot affect the design of the

cutting blade.
`

Figure #. Strain Analysis of Cutting Blade

Type Minimum Maximum

Stress 0.0007060 MPa 45.33 MPa

Strain 0.000000001771 0.0001845

Displacement 0 0.01864 mm
Table #. Summation of the Simulation done in the cutting blade
`

2. Shafts

2.1 Shredder Shaft (Longer)

Shown in the table below are the mechanical properties of the shaft where the

cutting blades are attached which are used and considered for the simulation of this

machine component.

Mass = 1.60969 kg

Volume = 0.000205056 m^3

Density = 7,850 kg/m^3

Weight = 15.775 N
Table #. Properties of the Cutting blade shaft

Applied Load

Table. #. Load Applied in the Cutting Blade Shaft

Stress Analysis

Using von mises stress analysis in solidworks it is possible to observe that the point

receiving the highest amount of stress is found at the end of the shaft due to high loads of torsion
`

combined with bending loads during the shredding process 3384 MPa, while the minimum

amount of stress is found at the middle of the shafts with 5.358MPa.

Figure #. Stress Analysis of the Shredder shaft

Deformation Analysis

The maximum deformation recorded during the simulation of the shredder shaft was

found to be at the center part of the shaft with a displacement value of 0.1184 mm, while the

minimum deformation was found at both ends of the shaft with 0.0001 mm displacement value.

Although the forces applied to the shaft by the shredding process may cause deformation, a value
`

of 0.1184 mm will not affect the shredding capability of the machine and would still be efficient.

Figure #. Deformation Analysis of the Shredder Shaft

Strain Analysis

From the values recorded throughout the simulation for the strain of the shaft with a

minimum value of 0.00001538 and maximum value of 0.01299 found near the end of the shaft

is not enough to cause any failure or provide any difficulties in the shredding process.
`

Figure #. Strain Analysis of the Shredder Shaft

Type Minimum Maximum

Stress 5.358 MPa 3384 MPa

Strain 0.00001538 0.01299

Displacement 0 0.1184 mm
Table #. Summation of the Simulation done in the cutting blade shaft
`

Cost Analysis

This section of the study tackles the cost and quantity of each machine component used

in the assembly of the water waste collector machine. Moreover, the total estimated costing of

the proposed machine as well as its manufacturing was expected to be included in this section.

Summary of Costing

Component Quantity Unit Price (Php) Total Price (Php)

ASTM A36 Steel 1 3,535.00 3,535.00

Plate (Hopper,
1200✕600mm)

Steel Frame 1 2,200.00 2,200.00

AISI 1045 Steel 2 875.00 875.00

(Shafts)

Rubber Belt 1 12,258.00 12,258.00

Single Phase Electric 1 9,750.00 9,750.00

Motor

AISI 1045 Steel 50 225.00 11,250.00

(Blades)

Gearbox 1 28,628.42 28, 628.42

Bearings 3 464.00 1392.00

Total amount for Php 69,888.42

Materials:

Table . List of Equipment, Cost per unit and Total Summary of Cost
`

Conclusion

This section contains the data that are generated from the study and lead to the following

conclusions:

1. The shredding process would be performed using the Corn stalk waste shredder

machine design. The machine's components include a motor and cutting blades.,

2. The materials utilized for the included components were chosen based on what is

commonly used and readily available on the market. As a result, there is enough

precedence to conclude that using steel as the material choice is appropriate for the

machine design and will allow it to function effectively and as planned.

3. The machine design proposed in this research is intended to shred corn stalks

successfully, but it does not guarantee work efficiency for other agricultural goods.

4. Based on the stress analysis performed on the shaft and blade, the stress values

generated were within the region where the manufactured design would not fail under

normal conditions. Along with this testing, the study of the safety factor indicated that the

design will be safe for use.

5. Given the global pandemic and the short time frame for completing this research, the

material list and pricing were dependent on online retailers. Given that prices on online

platforms tend to range from average to understated, it might be considered that the

projected material cost computed would be the mean price for the machine design, one of

which may potentially be higher.

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Appendix

Schematic Design of the Corn Stalk Waste Shredder Machine

`

Statement on the contribution of each team member

The tasks to be done for the design project were equally distributed among the members

of the group.

Barcelon, Arhon G.

Brin, Nica G.

Cunag, Christian Jan T.

Perez, Gian Carlo L.

BRIN, NICA G.
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