CERTIFICATION

The undersigned certifies that he has read and hereby recommend for acceptance by the Dar-
es-Salaam Institute of Technology project titled “Modification and Manufacture of Feed
Processing Machine for Husbandry”, in partial fulfillment of Bachelor of Engineering
degree in Mechanical Engineering.
Signature……………………
Prof C.T Mgonja
(Project Supervisor)
Date………………………

i
 DECLARATION
I, Hatibu Mohamed (150535482871), declare that this project is my own original work and
that it has never been presented, and will not be presented to any other institute for a similar
or any other degree award.
Signature……………………
Hatibu Mohamed
(Student)
Date………………………….

ii
 ABSTRACT
Feed processing machine is the machine that transform raw ingredients by mechanical means
to snack feed that is fit for consumption. In other word feed processing machine used to make
an animal feed. Animal feed is a feed given to domestic animals in the course of animal
husbandry. Thus this project report has been written to cover in brevity the analysis for the
modification of feed processing machine for husbandry which will make the machine
multipurpose for both fodder and forage. Forage is a plant material eaten by grazing livestock
which includes plant leaves, crop residue or immature grains crops. Fodder is a type of
animal feed in any agricultural feedstuff used specifically to feed domesticated livestock such
as cattle, rabbits, sheep, chicken etc. The machine will be multipurpose for making any kind
of feed needed for animal husbandry. This report involves introduction, literature review,
methodology, data collection and data analysis chapter which will guide to achieve the
project objective. Introduction provides the prior information about what the project is
concerned about. In literature review the several existing machines have been studied which
will give an initial step toward the modification of this machine, all of the specific objectives
have been discussed in this chapter, Literature review was taken from Dar-es-salaam Institute
of Technology (DIT) lectures text books, and internet browsing. Methodology chapter
illustrate the methods which will be used in order to achieve the project objectives. Data were
collected by literature review, direct observation and questionnaires to various expertise of
the concern. Data were collected from Dar-es-salaam Regional Vocational Training Centre
(VETA) Chang’ombe, Small Industries Development Organization (SIDO) Pugu road and
Gerezani kariakoo. This was done through visiting in the areas and see physically action of
how related machines are manufactured, interviewing and making questionnaires in order to
get full information about feed processing machines for husbandry. The collected data were
then analyzed at the Data analysis chapter. Data analysis provides a way to the selection of
best alternative according to the product design specifications which will be implemented.
And the most optimal design was obtained from among the alternative by considering
different factors such as manufacturing costs, efficiency, maintainability, durability, capacity
and safety were critically analyzed from which the optimum design was selected.
.

iii
 DEDICATION
I would like to dedicate this Project to the family; Mohamed Mbwana (father) and Amina
Hatibu (mother), brothers and sisters, for the fully support they have had towards all my
movements, especially an academic one. I do appreciate their efforts.
To my friends, and classmates (B.Eng. 16 ME) whom we shared all the ups and downs, I
appreciate you.

iv
 ACKNOWLEDGEMENT
I have to grant my grateful thanks to God for his bless, because without him nothing good
could happen to me. Next acknowledgement should go to the author of text books and
internet sites that have been used for references. They have provided the most suitable
materials for the preparation of this senior project one.
I would like to convey my sincere thanks to my classmates who have contributed directly
and indirectly to the whole period of preparation and writing this project. I thank them for
their support, valuable advice, suggestion and cooperation that have helped me to come out
with this project.
I thank my project supervisor Prof C.T Mgonja of mechanical department at Dar-es-salaam
Institute of Technology for his good assistance on supervision.
I would like also to thank Dr. Frederick Sanga for good theories on his project data
collection subject which helping me to achieve a nice performance on this project.
I highly appreciate the assistance provided by all lecturers including Dr. Malifedha J.M and
colleagues of mechanical Engineering Department at Dar-es-salaam Institute of technology
for their valuable advice and encouragement. They have played in monitoring, advising and
evaluating my project step by step up to this stage.
It is not easy to mention all names of peoples but I request to receive my thanks for those
who have participated in one way or another in order to make this project successful.
Lastly, I would like to thank my family member sister and aunt for their support in one way
another to complete this project.

v
 CONTENTS

Contents
CERTIFICATION....................................................................................................................i
DECLARATION......................................................................................................................ii
ABSTRACT.............................................................................................................................iii
DEDICATION.........................................................................................................................iv
ACKNOWLEDGEMENT.......................................................................................................v
LIST OF FIGURES.................................................................................................................x
LIST OF TABLES..................................................................................................................xi
LIST OF ABBREVIATIONS...............................................................................................xii
CHAPTER ONE.......................................................................................................................1
INTRODUCTION....................................................................................................................1
1.1 BACKGROUND..............................................................................................................1
1.2 PROBLEM STATEMENT..............................................................................................3
1.3 OBJECTIVE OF THE PROJECT....................................................................................3
1.3.1 MAIN OBJECTIVE OF THE PROJECT..................................................................3
1.3.2 SPECIFIC OBJECTIVE OF THE PROJECT...........................................................3
1.4 SIGNIFICANCE OF THE PROJECT.............................................................................3
CHAPTER TWO.....................................................................................................................4
LITERATURE REVIEW........................................................................................................4
2.0 Introduction......................................................................................................................4
2.1 Animal Feed.....................................................................................................................4
2.1.1 Fodder Animal Feed.................................................................................................4
2.1.2 Forage Animal Feed.................................................................................................4
2.2 Classification of Existing Feed Processing Machine.......................................................5
2.2.1 Existing Grass Cutter Machine.................................................................................5
2.2.2 Existing Feed Milling Machine.................................................................................8
2.3 Design Process...............................................................................................................11
2.3.1 Selection Design.....................................................................................................11
2.3.2 Parametric Design..................................................................................................11
2.3.3 Redesign..................................................................................................................11
2.3.4 Original Design......................................................................................................12
2.3.5 Adaptive Design......................................................................................................12

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 2.4 Steps of Engineering Design..........................................................................................12
2.4.1 The Conceptual Design...........................................................................................12
2.4.2 Detail Design..........................................................................................................13
2.4.3 Design Consideration.............................................................................................13
2.4.4 General Consideration in Design...........................................................................14
2.5 Manufacture of the Machine..........................................................................................15
2.5.1 Types of Manufacturing Processes.........................................................................16
2.6 Testing the Machine.......................................................................................................21
CHAPTER THREE...............................................................................................................22
METHODOLOGY.................................................................................................................22
3.1 Introduction....................................................................................................................22
3.2 Literature Review...........................................................................................................22
3.3 Data Collection...............................................................................................................22
3.3.1 Interviewing............................................................................................................22
3.3.2 Visiting and Observations.......................................................................................22
3.3.3 Consultation............................................................................................................23
3.3.4 Data Analysis..........................................................................................................23
CHAPTER FOUR..................................................................................................................24
DATA COLLECTION..........................................................................................................24
4.0 introduction....................................................................................................................24
4.1 Interview........................................................................................................................24
4.2 Materials.........................................................................................................................25
4.3 Observation....................................................................................................................26
4.3.1 Motor......................................................................................................................26
4.3.2 Sheet metal..............................................................................................................27
4.3.3 Angle Iron...............................................................................................................27
4.3.4 Bearing....................................................................................................................27
CHAPTER FIVE....................................................................................................................29
DATA ANALYSIS.................................................................................................................29
5.1 Design Specification......................................................................................................29
5.2 Conceptual Development...............................................................................................29
5.2 Selection of Suitable Design..........................................................................................29
5.3 Design Alternative.........................................................................................................30

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5.4 Determination of the Weight Factor..............................................................................30
5.5 Design Alternatives........................................................................................................31
5.5.1 Alternative A...........................................................................................................31
5.5.2 Alternative B...........................................................................................................32
5.5.3 Alternative c............................................................................................................34
5.5.4 Alternative D...........................................................................................................35
5.6 DESIGN CALCULATION.........................................................................................37
5.6.1 Main Specification..................................................................................................38
5.6.2 Determination of Angular Speed of the Motor.......................................................39
5.6.3 Torque Transmitted by Motor.................................................................................39
5.6.4 Belt Selection..........................................................................................................39
5.6.5 Determination of Angular Velocity of the Driven Pulley.......................................39
5.6.6 Determination of The Speed Ratio..........................................................................39
5.6.7 Computation of Belt Speed.....................................................................................39
5.6.8 Determination of Center Distance Between the Driver and
Driven Pulley...................................................................................................................40
5.6.9 Determination of Belt Length.................................................................................40
5.6.10 Determination of The Final Center Distance.......................................................40
5.6.11 Angle of Wrap.......................................................................................................40
5.6.12 Tension On Tight and Slack Side (T1 and T2).......................................................41
5.6.13 Resultant Force Acting On Driven Pulley Ta........................................................41
5.6.14 Number of Belt......................................................................................................41
5.6.15 Theoretical Beater Design....................................................................................42
5.6.16 Theoretical Design of the Blade...........................................................................42
5.6.17 Theoretical The Length of the Cut Pieces.............................................................43
5.6.18 Shaft Design..........................................................................................................43
5.6.19 Determination of The Shaft Diameter On Basis of Torque..................................48
5.6.20 Determination of Shaft Diameter On Basis of Bending Moment..........................49
5.6.21 Key Design............................................................................................................50
5.6.22 Shear Stress and Crushing Stress.........................................................................51
5.9 BEARING SELECTION.............................................................................................51
5.9.1 Determination of Radial and Axial Forces Acting On the Bearing........................51
5.9.2 Determination of Expected Bearing Life................................................................52
5:15 Design of feeding hopper.............................................................................................53
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 5.12. DESIGN OF DISCHARGE HOPER..........................................................................53
5.13. DESIGN OF THE FRAME........................................................................................53
5.15 MANUFACTURING PROCESS OF MODIFIED FEED PROCESSING MACHINE
FOR HUSBANDRY............................................................................................................54
CHAPTER SIX.......................................................................................................................56
CONCLUSION.......................................................................................................................56
6.1 Conclusion......................................................................................................................56
REFERENCES.......................................................................................................................57

ix
 LIST OF FIGURES
Figure 1.1: chaffed grass. Source (university, 2016)...............................................................1
Figure 1.2: feed processing machine for grass. Source.............................................................3
Figure2.1: Horse taken forage feed. Figure2.2: pelleted fodder feed...............................4
Source (wikipedia, 2018) Source (wikipedia, 2018)......................................4
Figure 2.3: Grasses pasture forage............................................................................................5
Source (wikipedia, 2018)...........................................................................................................5
Figure 2.4: Hand operated grass cutter machine. Source (farmersgrid, 2016)..........................5
Figure 2.5: motorized flywheel grass cutter machine. Source (machineries, 2018).................6
Figure 2.6: engine powered grass cutter machine.....................................................................7
Figure 2.7: Traditional tools used for cutting of grasses...........................................................7
Figure 2.8: Hammer mill machine............................................................................................8
Figure 2.9: attrition mill............................................................................................................9
Figure 2.10: Roller mill...........................................................................................................10
Figure 2.11: manual milling....................................................................................................11
Figure 2.12: Classification of manufacturing process............................................................16
Figure 2.13: Casting and Molding processes (1), (2) solid part is removed from the mold...17
Figure 2.14: Particulate process..............................................................................................18
Figure 2.16: Common machining operations..........................................................................19
Figure 4.1: Gerezani workshop...............................................................................................28
Figure 4.2: SIDO workshop....................................................................................................28
Figure 5.1: The function decomposition.................................................................................30
Figure 5.2: Motorized Feed Processor with Belt and Hammer Mill.......................................32
Figure 5.3: motorized feed processor with gear and hammer.................................................33
Figure 5.5: Engine Operated Feed Processor with Belt Drive and Attrition..........................36
figure 5.6; beater bar (flat bar)................................................................................................42
figure 5.7: hamme....................................................................................................................44
Figure 5.8; pin.........................................................................................................................44
Figure 5.9; free body diagram.................................................................................................46
figure 5.10; (a) FBD, (b) SFD, (c) BMD................................................................................47
Figure 5.11; key......................................................................................................................50

x
 LIST OF TABLE

Table 4.1: Data collected for grass cutter through interview from SIDO, GEREZANI and
VETA.......................................................................................................................................24
Table 4.2: Data collected for feed milling machine from SIDO, GEREZANI AND VETA..25
Table 4.3: Parts and proposed materials..................................................................................25
Table 4.4: Agricultural production in Tanzania (000 tones) principle crops..........................26
Table 4.5: motor supplied........................................................................................................26
Table 4.6: sheet metal available..............................................................................................27
Table 4.7: Angle iron available...............................................................................................27
Table 5.1: Weighting factor.....................................................................................................31
Table 5.2; Marks and average for an Alternative A................................................................32
Table 5.3: Marks and average for an Alternative B................................................................34
Table 5.4: Marks and average for an Alternative C................................................................35
Table 5.5: Shows marks and average of Alternative D...........................................................36
Table 5.6: Weighting factors, weight and score......................................................................37
Table 5.7: Operation sequence of manufacturing a modified feed processing machine for
husbandry.................................................................................................................................54
Table 1: project cost estimation sheet.....................................................................................59
Table 2; dimensions of standard v-belts according to IS: 2494 – 1974..................................61
Table 3; Dimensions of standard V-grooved pulleys according to IS: 2494 – 1974..............61
Table 4; Standard pitch lengths of V-belts according to IS: 2494 – 1974..............................62
Table 5; Recommended value for km and kt............................................................................62

LIST OF ABBREVIATIONS
Abbreviation Description
SIDO Small Industries Development Organization
DIT Dar-es-salaam Institute of Technology

xi
e.g. example
HRC Rockwell Hardness C
ME Mechanical Engineering
B.ENG Bachelor of Engineering
VETA Vocational Educational and Training
authority
PDS Product Design Specification

xii
 CHAPTER ONE
INTRODUCTION
1.1 BACKGROUND
Feed processing machine is the machine that produce animal feed from raw agricultural
ingredients such as such as corn, wheat, sorghum, forage etc. The machine use mechanical
means which are milling and cutting to transform raw agricultural ingredients to snack animal
feed that is fit for consumption. The feed processing machine aims to make an animal feed.
Animal feed is a feed given to domestic animals in the course of animal husbandry. Animal
feeds have been broadly classified as follows: concentrates which are high in energy, contains
mainly grains and their byproducts, or is prepared from high protein oil meals or cakes, and
byproducts resulting from sugar beets and sugarcane process. Roughages which are grass
pastures, or plant parts like hay, silage, root crops, straw, and Stover. Diets given to different
species are all not the same. For example, livestock animals are fed on a diet that consists
mainly of roughages, while poultry, swine, and fish are fed with concentrates. Livestock in a
feedlot may be fed with energy feeds which usually comes from grains, supplied alone or as
part of a total mixed ration
To achieve higher livestock productions, sufficient feed and fodder supply to the livestock is
essential. Animal feeding is very important aspect of livestock husbandry. It is very necessary
to have effective utilization of available feed sources. Chaffing fodders and straws to small
pieces and then feeding to animals improve the digestibility, palatability of feed and
conserves energy that they have to use in mastication. To feed the chopped forage may
increase the utilization and digestion ratio and make silage can improve the quality and taste
agreeableness of forage, achieving the goal to store the green feed over a long period of time
and minimize nutrition lose. Chaff is hay cut into small pieces for feeding to livestock
(Mohan, 2004).

1
 Figure 1.1: chaffed grass. Source (university, 2016)
The machine involves two process milling and cutting. Where milling is the process of
grinding or crushing the material into a small particle. Milling of raw agricultural products by
mechanical action involves several forces like compression, shearing, crushing, cutting,
friction and collision. The particle size of the animal feed is very important in the animal feed
production; smaller particle sizes increase the number of particles and the surface area per
unit volume which increase access to digestive enzymes. Other benefits are increased ease of
handling and easier mixing of ingredients. Cutting is separation of physical object into two or
more portions through the application of acute directed force.
Feed processing machine plays an important role because it helps to produce high capacity of
animal feed from agricultural product, also reduces the size of the raw agricultural products
so that it can be taken easily by animal, unlike manual processing of animal feed processing
machine does not saves time so it become uneconomical to use it.
The existing feed processing machine which is made at DIT in year 2018 by Vestina Vedasto,
process only one type of feed which is grass. Grass cutter machine is the machine that used to
cut a grass into small pieces which will simplify digestion, the machine was used to cut only
one type of feed which is grass(chaff) for livestock. The existing machine required the
collector to use more power in collecting the processed feed. The machine also involved
processing only one type of feed which is grass for livestock keeping
The existing machine which is the grass cutting machine shown in the figure 1.2 was only
reducing the size of the grass so that they can be eaten smoothly by livestock especially
herbivorous, when there is a need to produce feed for poultry, fish, swine etc, the other
machine have to be used in order to produce the required feed.
Generally, it become uneconomical in terms of time and cost to have different kinds of
machines so as to produce different types of feed for different livestock. Therefore, an
existing grass cutting machine has to be modified so as to become a multipurpose machine

2
 that will cut the grass for cattle (herbivorous) and produce feed for other animal such as
poultry, fish, swine etc, which is from raw agricultural products.

1.2 PROBLEM STATEMENT

The existing feed processing machine process only one kind of feed which is grass that is
taken by cattle(herbivorous), the problem arises when there is a need to process feed for other
husbandry like poultry, fish, swine etc. where it requires the use of different kinds of machine
to process different kind of feed for different livestock which is uneconomical items of cost
and time.

Blade cutter belt

pulley

motor

Figure 1.2: feed processing machine for grass. Source (DIT, 2017)
1.3 OBJECTIVE OF THE PROJECT
1.3.1 MAIN OBJECTIVE OF THE PROJECT
The main objective of this project is modification and manufacture feed processing machine.
1.3.2 SPECIFIC OBJECTIVE OF THE PROJECT
I. To examine the existing feed processing machine for husbandry
II. To design feed processing machine
III. To manufacture machine

3
IV. To test the machine
1.4 SIGNIFICANCE OF THE PROJECT
I. It is safer compared to the existing machine.
II. The machine will operate two function which are cutting grass and also it will mill
grains for husbandry at the same time.
III. It is simple to be maintained.
IV. It is easy to use.
V. It will help peasants to save time and energy for cutting and milling of grains.

CHAPTER TWO
LITERATURE REVIEW
2.0 Introduction
Feed is any substance consumed to provide nutritional support for an organism. It contains
essential nutrients, such as carbohydrate, fats, protein, vitamins and minerals.
Feed processing is the transformation of agriculture products into feed or of one form of feed
into other forms. Feed processing includes many forms of processing feed from grinding
grains to make raw flour to home cooking to complex industrial methods used to make
convenience feeds
2.1 Animal Feed
Animal feed is feed given to domestic animals in the course of animal husbandry. The
process of feeding animals need time for the livestock keeper to prepare feed for their
animals. There are two basic types of animal feed: fodder and forage.
2.1.1 Fodder Animal Feed
"Fodder" refers to particularly feeds given to the animals including plants cut and carried to
them it includes hay, straw, silage, compressed and pelleted feeds
Pellet are small particles typically rounded, spherical, or cylindrical body (as of feed or
medicine) created by compressing an original material through a screw conveyor and forced
to come out through an orifice (nwaigwe, et al., 2003).

Figure2.1: Horse taken forage feed. Figure2.2: pelleted fodder feed.

4
 Source (wikipedia, 2018) Source (wikipedia, 2018)

2.1.2 Forage Animal Feed

is a plant material (mainly plant leaves and steams) eaten by grazing livestock. Historically
the term forage has meant only plants eaten by the animals directly as pasture, crop residue.

Figure 2.3: Grasses pasture forage

Source (wikipedia, 2018)

5
2.2 Classification of Existing Feed Processing Machine
2.2.1 Existing Grass Cutter Machine
2.2.1.1 Hand Operated Grass Cutter Machine
The grass cutter consists of a feeding tray, curves blade fixed on ring loaded lever, anvil
which also acts as cutting blade and suitable frame work. The cutting action is similar to the
shearing machine used in the workshop. The blade is made from medium carbon steel or low
alloy steel, hardened and tempered to about 45 HRC. For operation, fodder is fed in the tray
pushed by one hand and the other hand and a leg actuates the curved cutting blade
progressively shears the fodder into small pieces. It is used to cut chaff, grass and dry fodder
crop into bits for feeding the animal (farmersgrid, 2016).
Figure 2.4: Hand operated grass cutter machine. Source (farmersgrid, 2016)
2.2.1.2 Motorized Flywheel Chaff Cutter Machine
The flywheel is made of cast iron or steel for mounting blades and storing energy for cutting
chaff during operation. The flywheel should be heavy and balanced for cutting of chaff with
efficiency. The flywheel shall have two arms. Each arm shall be provided with one square
hole for fixing the handle, three holes for fixing the blades and six tapped holes for fixing the
bolts for blade setting adjustment. The weight of the flywheel shall not be less than 24 kg. the
flywheel is connected to the pulley of motor by belt which transmit rotation energy from
motor to the flywheel which cut he chaff (machineries, 2018).

Figure 2.5: motorized flywheel grass cutter machine. Source (machineries, 2018)

6
2.2.1.3 Engine Powered Chaff Cutter Machine
This is similar to the motorized chaff cut but the difference is on the source of power. Engine
powered chaff cutter machine use engine as the source of power. The flywheel of the engine
is connected to the flywheel which have blade for cutting by belt. Also the engine use fuel
energy as the source of power generation (chintaman, 2018).

Figure 2.6: engine powered grass cutter machine. Source (chintaman, 2018)
2.2.1.4 Traditional Grass Cutting Tools
These were tool which used by people to cut grass before design and manufacturing
nowadays machines. Some of traditional tools which were used are sickles, Slashers and
grass hook (ebay, 2018).

Figure 2.7: Traditional tools used for cutting of grasses. Source (ebay, 2018)

7
2.2.2 Existing Feed Milling Machine
2.2.2.1 Hammer Mill Machine
Hammer mills are the mostly impact grinders with swinging or stationary steel bars forcing
ingredients against a circular screen or solid serrated section designated as a striking plate.
Material is held in the grinding chamber until it is reduced to the size of opening in the
screen. The number of hammer on a rotating shaft, their size, arrangement, sharpness, the
speed of rotation, wear patterns and clearance at the tip relative to the screen or striking plate
are important variables in the grinding capacity and the appearance of the product. Heat
imparted to the material, due to the work of grinding, is related to the time it is held within
the chamber and the air floor characteristics. Impact grinding is most efficient with dry, low

fat ingredients, although many other materials may be reduced in size by proper screen
selection and regulated intake. Most of hammer mills have a horizontal drive shaft which
suspends vertical hammers but for some ingredients such as dried animal byproducts
(wikipedia, 2018).

8
 Figure 2.8: Hammer mill machine. source (machinery, 2018)

2.2.2.2 Attrition Mill

attrition mills use the hammer mill principle to certain extent i.e., shattering by/impact.
However, they also impact a shearing and cutting action. Grinding is done between two discs
equipped with replaceable wearing surfaces. One or both of these discs is rotated, if both,
they rotate in opposite directions. When one discs is rotated and the other stationary, the
assembly is used for shredding and deferring. Often materials which have been coarsely

motor

Gear box

attritor

cover

ground by other mills, are passed through an attribution mill for blending or smoothing out an
ingredient or mixture containing liquids which may have clumps. The discs of an grains
attrition
mill are generally in a vertical position so that materials not capable of reduction can pass by
gravity out of grinding area (sciencedirect, 2018).
Figure 2.9: attrition mill. Source (sciencedirect, 2018)

9
2.2.2.3 Roller Mill
A combination of cutting, attrition, and crushing occurs in roller mills. These are smooth or
corrugated rolls rotating at the same speed set at a pre-determined distance apart with
material passing between the two. A tearing action may be added by operating the rolls at
different speeds and by corrugations which are different for each roll i.e., the top roll may
have off radial spiral corrugations and the bottom roll lateral corrugations. This last type,
called a “Le page cut” is used in making granules from hard pellets, as it provides a breaking
surface without much impact to cause dust. Roll grinding is economical but limited to
materials which are fairly dry and low in fat (finedictionary, 2018).

rollers

pulley

hopper

grains

Figure 2.10: Roller mill. source (finedictionary, 2018)

2.2.2.4 Manual Milling

Typical African wooden mortar, pestle, and winnowing basket were used in the study.Hand
pounding was found to be very laborious, requiring about 1 hour to process 2-3 kg of

10
sorghum grain by an experienced adult Tanzanian lady. Though up to now this method is still
applicable in rural areas but it is very monotonous job (shutterstock, 2018).

Figure 2.11: manual milling. Source (Muheza, 2018)

2.3 Design Process
Engineering design refers to the application of scientifically, mathematical and economical
skills so as to get a solution to a problem that has never being solved in the past or new
solutions to the existing problems that aim at solving the problem in a better way (ullman,
2009)
Design Consideration
Main considerations in the development of the feed processing machine include: choice of
material of construction (mild steel material will be used for the parts of the machine),
simplicity, efficiency and cost. A feed processing machine will be designed and developed. It
will be portable and simple to operate (khurmi & gupta, 2005). There are generally five types
of design in mechanical engineering. The following are the types of engineering design
2.3.1 Selection Design
In selection design, the design engineer simply picks out an existing solution that meets the
specifications and requirements of the design problem. An example is selecting a proper
bearing for a wheel. The key to a successful selection design is gaining a full understanding
of both the design need as well as the limitations of existing solutions (ullman, 2009).

11
2.3.2 Parametric Design
In parametric design an optimal design solution is found by finding proper parametric values
a simple example is the design of a rope bridge the rope size is a parameter that is varied until
the bridge can support the necessary weight (ullman, 2009).
2.3.3 Redesign
In redesign an existing solution is modified so as to get a better solution to the particular
problem. The better solution may be driven by factors such as changing needs, the desire to
reduce costs or the availability of new technology. Example is the design of a better mouse
trap (ullman, 2009).
2.3.4 Original Design
This form of design is at the top of the hierarchy. It employs an original, innovative concept
to achieve a need. Sometimes, but rarely, the need itself may be original. A truly original
design involves invention. Successful original designs occur rarely, but when they do occur
they usually disrupt existing markets because they have in them the seeds of new technology
of far reaching consequences. The design of the microprocessor was one such original design
(Sanga, 2018).
2.3.5 Adaptive Design
This form of design occurs when the design team adapts a known solution to satisfy a
different need to produce a novel application. For example, adapting the ink-jet printing
concept to spray binder to hold particles in place in a rapid prototyping machine. Adaptive
designs involve synthesis and are relatively common in design (Sanga, 2018).
2.4 Steps of Engineering Design
Engineering design is a science and an art and for this reason it needs to be done in a
systematic way by following a set of rules and principles. Always in engineering design there
are a group of important factors to be taken into consideration and each of them are contained
in the steps that are to be followed in the engineering design process. The following are the
major steps in the engineering design process (Sanga, 2018).
2.4.1 The Conceptual Design
This is the early stage of the design process in which the broad outlines of functions and form
of something are anticipated. It includes the design interactions, experiences, processes and
strategies. It involves understanding of people needs and how to meet them with products,
services and processes. It commonly involves sketches and models (wikipedia, 2018). The
conceptual design is mainly made up of four contents which are as follows (Sanga, 2018).

12
 i. Defining the problem
This is the initial stage in the engineering design in which the engineer is able to develop an
idea in the mind based on a particular problem that has being observed in the society and next
the engineer must clearly define the problem.
ii. Research
After the problem has being clearly defined what must follow is the gathering of information
concerning the particular problem to see what are the possible solutions, what have others
done and what where the difficulties encountered. This will help to give a clearer picture of
what is needed to be done.
iii. Generate solutions
This is where the legal work starts with the information at the disposal of the engineer he or
she will need to use the information to generate a solution this is where the creativity and
innovative part of the engineer is applied. He or she might also consult other engineers so as
to get more ideas concerning the solutions of the problem.
iv. Selection of the best solution
After a number of solutions have been generated the engineer will be required to take the best
solution from the existing ones. This is a done by a mathematical analysis called the
weighting method in which a number of design parameters or specifications are chosen and
are weighted depending on their significance. Finally, each of the solutions is weighted
according to the parameters chosen and the best solution is obtained.
2.4.2 Detail Design
Detailed design is a phase where the design is refined and plans, specifications and estimates
are created. Detailed design will include outputs such as 2D and 3D models as well cost build
up estimates. Procurement plans etc. This phase is where the full cost of the project is
identified. This stage involves analysis and calculations and finally the detailed and assembly
drawing.
Important design criteria
Function: The design produced should be able to operate as per product design specifications
which means that at the end the produced mechanism should be able to work and perform its
intended tasks properly as anticipated.
Form: This refers to the shape and the configuration of the design that at the end of the day
the designed mechanism should have the appropriate shape and arrangement of components
(Sanga, 2018).

13
2.4.3 Design Consideration
In the design consideration we will look the following features.
i. Strength: A component should not fail or have residual deformations under the effect
of the forces that act on it. This is satisfied if the induced stress is less than the
material strength σ ≤ [S]. The necessary and sufficient strength of the part with a
given load and a selected material is ensured by such dimensions and shapes, which
preclude damage and residual deformations. A component can also fail because of
damaged working surfaces induced by the very high stress or very small area (khurmi
& gupta, 2005).
ii. Rigidity: Is the ability of parts to resist deformations under the action of forces.
Proper rigidity is necessary to ensure that the mated elements and machine as a whole
operate effectively. In many cases this parameter of operating capacity proves to be
most important. Therefore, apart from the strength calculations rigidity of a number of
parts is also calculated by comparing the actual displacements (deflections, angles of
turn, and angles of twist) with allowable (rated) displacements (khurmi & gupta,
2005).
iii. Wear Resistance: Wear is the principal cause of putting machine elements out of
commission. Problems: frequent stops, loss of machine accuracy etc. Calculations of
wear are usually of an arbitrary nature and carried out together with calculations of
strength (khurmi & gupta, 2005).
iv. Heat resistance: The liberation of heat involved in the working process or sometimes
due to friction between moving surfaces, causes the components of some machines to
operate under conditions of increased temperature. An increased temperature (T >
100oC) impairs the lubricating ability of oils; Continuous operations involving
temperatures > 300-400oC causes slow plastic deformations called creep. Thermal
deformations may reduce the accuracy of a machine. Effective cooling and special
calculations for heat to find the working temperature of the machine elements
evaluate the working stresses and compare them with the creep limits for the material
of the part (khurmi & gupta, 2005).
v. Resistance to vibrations: The term implies the ability of a machine to operate at the
assigned speeds and loads without impermissible oscillations Dynamic analysis after
finalizing the design to avoid inherent unbalances (khurmi & gupta, 2005).

14
2.4.4 General Consideration in Design
i. Type of load and stresses induced; to design a machine part it is necessary to know
the forces, which the part must sustain (khurmi & gupta, 2005).
ii. Motion of the parts or kinematics of the machine: Forces and their relations change
during the motion of the part. The motion of the part may be (khurmi & gupta, 2005):
a) Rectilinear motion
b) Curvilinear motion
c) Constant or variable velocity
d) Constant or variable acceleration
iii. Selection of materials: Body of the component is the material. The designer should
have thorough knowledge of the properties of the materials and their behavior under
working conditions. Important characteristics of materials are: strength,
stiffness/flexibility, durability, weight, resistance to heat, corrosion and wear, ability
to cast, weld or hardened, machinability, electrical or magnetic properties etc. Avoid
the use of scarce materials (khurmi & gupta, 2005).
iv. Form and size of the parts: The smallest practicable cross section may be used to
ensure that the stresses induced are reasonably safe and easy to machine. Part or
assembly should not involve undue stress concentrations. Small weight and minimum
dimensions should be the criteria (shape and material) (khurmi & gupta, 2005).
v. Production soundness: The component should be designed such that its production
requires the minimum expenditure of labor and time (khurmi & gupta, 2005).
vi. Number to be manufactured: The number of components to be manufactured affects
the design in a number of ways (khurmi & gupta, 2005).
vii. Cost of construction: The cost of construction of a part is one of the most important
considerations involved in design. The aim is to reduce the manufacturing costs in any
circumstance (khurmi & gupta, 2005).
viii. Safety: The shape and dimensions of the part should ensure safety of the personnel
responsible for not only its manufacture but during its operation in a machine also
(khurmi & gupta, 2005).
ix. Workshop facilities: A design engineer should be familiar with the limitations of the
available workshop. Here, the policy to manufacture or to buy should be decided
(khurmi & gupta, 2005).
x. Use of standard parts: The use of standard parts is closely related to cost. The standard
or stock parts should be used whenever possible: gears, pulleys, bearings and screws,
15
 bolts, nuts, pins. Variety (number and size) of such parts should be as few as possible
(khurmi & gupta, 2005).
xi. Conformance to standards and codes: Any part should confirm to the standards
covering the shape, grade and type of material and safety codes where applicable
(khurmi & gupta, 2005).
2.5 Manufacture of the Machine
Manufacturing is the application of physical and chemical processes to alter the geometry,
properties, and/or appearance of a given starting material to make parts or products;
manufacturing also includes assembly of multiple parts to make products. The processes to
accomplish manufacturing involve a combination of machinery, tools, power, and labour, as
depicted. Manufacturing process is a designed procedure that results in physical and/or
chemical changes to a starting work material with the intention of increasing the value of that
material (Kalpakjian & Schmid, 2005).
2.5.1 Types of Manufacturing Processes
A manufacturing process is usually carried out as a unit operation which means that it is a
single step in the sequence of steps required to transform the starting material into a final
product. Manufacturing operations can be divided into two basic types: (1) processing
operations and (2) assembly operations. A processing operation transforms a work material
from one state of completion to a more advanced state that is closer to the final desired
product. It adds value by changing the geometry, properties, or appearance of the starting
material. In general, processing operations are performed on discrete work parts, but certain
processing operations are also applicable to assembled items (e.g., painting a spot-welded car
body). An assembly operation joins two or more components to create a new entity, called an
assembly, subassembly, or some other term that refers to the joining process (e.g., a welded
assembly is called a weldment). A classification of manufacturing processes is presented in
Figure below (Groover, 2017).

16
 Figure 2.12: Classification of manufacturing process. Source (Groover, 2017)
2.5.1.1 Shaping Process
Shaping Processes most shape processing operations apply heat, mechanical force, or a
combination of these to effect a change in geometry of the work material. There are various
ways to classify the shaping processes. The classification used in this book is based on the
state of the starting material, by which we have four categories:
Solidification processes; in which the starting material is a heated liquid or semifluid that
cools and solidifies to form the part geometry. The starting material is heated sufficiently to
transform it into a liquid or highly plastic (semifluid) state. Nearly all materials can be
processed in this way. Metals, ceramic glasses, and plastics can all be heated to sufficiently
high temperatures to convert them into liquids. With the material in a liquid or semifluid
form, it can be poured or otherwise forced to flow into a mold cavity and allowed to solidify,

17
thus taking a solid shape that is the same as the cavity. Most processes that operate this way
are called casting or molding. Casting is the name used for metals, and molding is the
common term used for plastics. This category of shaping process is depicted in Figure 2.14
below (Groover, 2017).
Figure 2.13: Casting and Molding processes (1), (2) solid part is removed from the mold.
Source (Groover, 2017)
i. Particulate processing; in which the starting material is a powder, and the powders are
formed and heated into the desired geometry. In particulate processing, the starting
materials are powders of metals or ceramics. Although these two materials are quite
different, the processes to shape them in particulate processing are quite similar. The
common technique involves pressing and sintering, illustrated in Figure below in
which the powders are first squeezed into a die cavity under high pressure and then
heated to bond the individual particles together (Groover, 2017)

Figure 2.14: Particulate process. Source (Groover, 2017)

ii. Deformation processes; in which the starting material is a ductile solid (commonly
metal) that is deformed to shape the part. In deformation processes, the starting work
part is shaped by the application of forces that exceed the yield strength of the
material. For the material to be formed in this way, it must be sufficiently ductile to
avoid fracture during deformation. To increase ductility (and for other reasons), the
work material is often heated before forming to a temperature below the melting
point. Forging, in which two halves of a die squeeze the work part, causing it to
assume the shape of the die cavity. Extrusion, in which a billet is forced to flow
through a die orifice, thus taking the cross-sectional shape of the orifice. Deformation
processes are associated most closely with metalworking and include operations such
as forging and extrusion, shown in Figure (Kalpakjian & Schmid, 2005).

18
 Figure 2.15: Deformation Processes. Source (Groover, 2017)
iii. Material removal processes: in which the starting material is a solid (ductile or
brittle), from which material is removed so that the resulting part has the desired
geometry. Material removal processes are operations that remove excess material
from the starting work piece so that the resulting shape is the desired geometry. The
most important processes in this category are machining operations such as turning,
drilling, and milling. Turning, in which a single-point cutting tool removes metal from
a rotating work piece to reduce its diameter. Drilling, in which a rotating drill bit is
fed into the work to create a round hole. Milling, in which a work part is fed past a
rotating cutter with multiple edges. These cutting operations are most commonly
applied to solid metals, performed using cutting tools that are harder and stronger than
the work metal. Grinding is another common process in this category. Other material
removal processes are known as non-traditional processes because they use lasers,
electron beams, chemical erosion, electric discharges and electrochemical energy to
remove material rather than cutting or grinding tools. It is desirable to minimize waste
and scrap in converting a starting work part into its subsequent geometry. Certain
shaping processes are more efficient than others in terms of material conservation.
Material removal processes (e.g., machining) tend to be wasteful of material, simply
by the way they work. The material removed from the starting shape is waste at least
in terms of the unit operation. Other processes, such as certain casting and molding
operations, often convert close to 100% of the starting material into final product.
Manufacturing processes that transform nearly all of the starting material into product
and require no subsequent machining to achieve final part geometry are called net
shape processes. Other processes require minimum machining to produce the final
shape and are called near net shape processes (Groover, 2017).

19
 Figure 2.16: Common machining operations. Source (Groover, 2017)
2.5.1.2 Property-Enhancing Processes
Property-Enhancing Processes is the second major type of part processing is performed to
improve mechanical or physical properties of the work material. These processes do not alter
the shape of the part, except unintentionally in some cases. The most important property-
enhancing processes involve heat treatments, which include various annealing and
strengthening processes for metals and glasses. Sintering of powdered metals and ceramics is
also a heat treatment that strengthens a pressed powder metal work part (Groover, 2017).
2.5.1.3 Surface Processing
Surface processing operations include (1) cleaning, (2) surface treatments and (3) coating and
thin film deposition processes.
i. Cleaning:
Cleaning includes both chemical and mechanical processes to remove dirt, oil, and other
contaminants from the surface. Surface treatments include mechanical working such as shot
peening and sand blasting and physical processes such as diffusion and ion implantation
(Groover, 2017).
ii. Surface treatment:
Surface treatments include mechanical working such as shot peening and sand blasting, and
physical processes such as diffusion and ion implantation (Groover, 2017).
iii. Coating and thin film deposition process:
Coating and thin film deposition processes apply a coating of material to the exterior surface
of the work part. Common coating processes include electroplating, anodizing of aluminum,
organic coating (call it painting), and porcelain enameling. Thin film deposition processes
include physical vapour deposition and chemical vapour deposition to form extremely thin
coatings of various substances (Groover, 2017).
Several surface-processing operations have been adapted to fabricate semiconductor
materials into integrated circuits for microelectronics. These processes include chemical

20
vapour deposition, physical vapour deposition, and oxidation. They are applied to very
localized areas on the surface of a thin wafer of silicon (or other semiconductor material) to
create the microscopic circuit.
2.5.1.4 Assembly Operation
The second basic type of manufacturing operation is assembly, in which two or more separate
parts are joined to form a new entity. Components of the new entity are connected either
permanently or semi permanently. Permanent joining processes include welding brazing
soldering and adhesive bonding. They form a joint between components that cannot be easily
disconnected. Certain mechanical assembly methods are available to fasten two or more parts
together in a joint that can be conveniently dis assembled. The use of screws, bolts and other
threaded fasteners are important traditional methods in this category. Other mechanical
assembly techniques form more permanent connection, these include rivets, press fitting and
expansion fits. Special joining and fastening methods are used in the assembly of electronic
products. Some of the method are identical to rare adaptation of the preceding processes, for
example, soldering. Electronic assembly is concerned primarily with the assembly of
components such as integrated circuit packages of printed circuit boards to produce the
complex circuits used in so many of today’s products (Groover, 2017).
2.6 Testing the Machine
After all the above processes all that is left is to test the machine and record the results. Also
after testing the machine the Engineer will need to answer the questions from the audience
and take their opinions so as to help in the improvement of the product based on the market
demands (Gilson, 2018).

21
 CHAPTER THREE
METHODOLOGY
3.1 Introduction
This chapter consists of methodological issues which include the appearance of the
Methodological approach, scheme of the study, project design, techniques of data collection,
Sampling procedures, data analysis methods and data presentation. It gives an overview or
act as a stepping stone of the project. Furthermore, it gives the information progress of the
design of different machine available. In order to achieve the objectives of this project, the
following methods have been used as the basis for analysis:
3.2 Literature Review
Literature review gives an opportunity to refer to the related topic similar to this project, and
thus the other existing types of feed processing machine, working principle of each type has
been studied; also materials and manufacturing process to gain familiarity of what is done by
the others on this case in order to get some direction where to start with my project. This
section is referring to the main framework of the project, where the information extracted are
based on the specific objective of this project. This information is mainly obtained through
browsing in internet search engine, lecture notes, engineering journals and reading related
engineering books so that the information obtained reveals the gap that is to be bridged.
3.3 Data Collection
This section involves the important information seem to contribute ideas in designing the
appropriate feed processing ingredients of formulated animal feed, and their characteristics,
knowing the milling and cutting mechanism, materials to manufacture machine in order to
fulfill the main objective of the project. Both primary and secondary data was collected
through visiting, interviews, observations and consultation while others are extracted from
written documents.
3.3.1 Interviewing
In order to get information about design methodology of a feed processing machine,
materials, as well as technology of manufacture, and marketing aspect, a survey has been
made to have a general idea and the facts to various places in Dar-es-salaam and Coast region
to animal feed preparation and what are the challenges facing them.
3.3.2 Visiting and Observations
This involved visiting a place, collecting information through reality of the situation. This
process allowed getting information with the evidence on how animal feed are processed,
produced, and packed.
22
3.3.3 Consultation
Different qualified persons such as peasants, engineers, supervisors and other experts have
been consulted to contribute their ideas.
3.3.4 Data Analysis
The purpose of data analysis was to know the size of each component and shape of the
machine, determination of shaft diameter and its rotation rate and other requirements for feed
processing. The following designing issues were critically thought of;
i. Analyzing the probable solution
Basing on the collected data, the probable solution was critically analyzed by considering
three alternatives. At last the best alternative was selected from three compared alternatives.
ii. Determination of feed processing machine parameters
Calculations to know the capacity, weight and other parameters shall be performed.
iii. Design of the system
This process will enable the parts and shapes of the feed processing machine to be known.
iv. Calculations
The sizes of the components of the feed processing machine shall be determined through
calculation process.
v. Drawings
The detail drawings which determine the size and the shape of each part used to manufacture
the feed processing machine and assembly drawing with its part list to represent actual
machine to be manufactured shall be produced and used to direct a technician to manufacture
and assemble the machine.
vi. Manufacturing the Machine
After having the specifications of the materials and drawings, the machine shall be
manufactured basing on the dimensions obtained.
vii. Testing the Machine
The machine manufactured can be tested to observe its performance and if it satisfies the
intended goal and requirements.
viii. Report writing
A detailed report which explains all procedure used to conduct this project and
recommendations shall be written in this report book. This involves compiling the general
task performed from the beginning up to the general design and achievement of the design.

23
 CHAPTER FOUR
DATA COLLECTION
4.0 introduction
Data were collected from various sources through: literature review, consultation, and
observations. One of the greatest goal of Data Collection is to look for product design
specifications (PDS), that will meet need of the society in need, in terms of capacity, cost,
durability and working environments, user ergonomics, etc. This information is important and
useful during design, and hence, modification manufacture of FEED PROCESSING
MACHINE FOR HUSBANDRY. Through consultations and Observation, information was
collected in Dar-es-salaam, specifically GEREZANI workshops. Through literature review,
information was obtained in different books for designing, and through internet.
4.1 Interview
Through Interviews, the data below were obtained:
Table 4.1: Data collected for grass cutter through interview from SIDO, GEREZANI and
VETA
S.n Questions Answers
o
1 What is the maximum grass cutting for livestock per 100 kg per day
day?
2 Do you cut all type of grass? Yes, but it will depend with
the requirements of the
livestock
3 There is any injury do you get when feeding the No, there is no any injury
grass for livestock? you get if you wear grass
4 Which problem do you face during cutting or after The problem face is after
cutting the grass? cutting the grass are so
scatted it take long time to
collect the cutting grass
manually
5 Which effect do you get when collecting the grass Time consuming
manually?
6 How is time affect production? Less production
7 Do you need to modify feed processing machine? Yes, there is a need to do so

24
 8 Do you believe it would help solve the problem? Yes, it would be helpful
9 How will it be helpful? All challenges will almost
be overcome, plus it will
increase the production
10 So how do you like the feed processor machine to be In a manner as to reduce the
improved time consuming
11 If technology is there at what cost will you afford Sincerely we are low income
businessman if it were
possible not to be too high

Table 4.2: Data collected for feed milling machine from SIDO, GEREZANI AND VETA
S.No Questions Answers
1 What are the maximum milling feed produced for 60 kg per day
husbandry
2 Which type of feed do you mill Maize sorghum and small
fish
3 There is any injury do you get when feeding the No, there is no any injury
feed

4.2 Materials
After examining the existing machine, the following are the proposed materials for different
parts of the machine to be designed.
Table 4.3: Parts and proposed materials
S.No Part Material
1 Machine frame Plain carbon steel
2 Pulley Aluminum
3 Shaft Plain carbon steel
4 Angle iron Plain carbon steel

25
Table 4.4: Agricultural production in Tanzania (000 tones) principle crops
Crop 2001/2002 2002/2003 2003/2004 2004/2005
Maize 2705 2322 3232 3288
Rice 683 850 906 1018
Sorghum 140 213 386 784
Wheat 77 75 74 110
Total 3605 3460 4598 5200

4.3 Observation
Observation was done in Kariakoo at Gerezani to observe how the feed processing machine
how they manufacture. Different feed processor where observed I also got to see the
weakness of this machines. The consequences of using feed processing machine means were
easily noticed through observation. Through these observations a lot of important information
was collected that helped further advance the project by providing more insights on how the
feed processor machine can be improved.
4.3.1 Motor
Table 4.5: motor supplied
POWER PHASE VOLTAGE RPM TORQUE NM COST TSH
(KW)
0.3 1 220 700 3.8 180,000
0.5 1 220 900 5.8 200,000
1.1 1 220 630 15.2 230,000
3 3 400 930 29 400,000
5.5 3 400 713 79 600,000
11 3 400 720 145 1000,000

26
4.3.2 Sheet metal
All sheet material available were in standard area of 2400x1200 mm
Table 4.6: sheet metal available
Thickness Cost Tsh Material thickness Cost Tsh
Material
Mild steel 1mm 50000 Stainless steel 1mm 75000
2mm 850000 2mm 100000
3mm 150000 3mm 200000
4mm 200000
5mm 250000

4.3.3 Angle Iron

Mild steel angle iron was available in different range and were in standard length of 6000mm
below is a sample of size and cost
Table 4.7: Angle iron available
Size mm Cost in Tsh.
12.5X2 20000
25X3 45000
50X6 55000

4.3.4 Bearing
The following bearing was found to be common supplied in different size according to ISO
standard
i. Ball bearing,
ii. Roller Bearings,
iii. Roller thrust bearing, and
iv. Ball Thrust Bearings

27
Figure 4.1: Gerezani workshop.

Figure 4.2: SIDO workshop

28
29
 CHAPTER FIVE
DATA ANALYSIS
5.1 Design Specification
In order to obtain to obtain high efficiency and reliable, the machine was designed based on
the following consideration;
i. The machine should be relatively cheap.
ii. Easley to operate
iii. Safe
iv. Durable
v. The equipment should be made with right materials.
vi. The component parts should be easily replaceable in case of any damage.
vii. The machine should save time.
5.2 Conceptual Development
Design process has some stages to consider. The early stage is conceptual development, this
deal with development of varieties of the design where the optimal solution is found. In this
chapter several designs have been developed and the best alternative is selected. The major
reasons for their differences are capacity of the machine, efficiency of the machine and other
parameters which will assist in obtaining the optimal solution that will solve the problem
statement of the design.
In order to obtain the optimal design solution of the feed processing machine, the following
are considered to add major impact so as to achieve better solution with optimal safety,
ergonomics, capacity, cost, and durability and factors such as.
i. Mechanisms should be easy to use
ii. Material to be use
iii. Source of power
iv. Power transmission mechanism
5.2 Selection of Suitable Design
In order to get the best alternative solution of this design, the following factors should be
considered:
i. Production cost
ii. Durability
iii. Capacity
iv. Maintainability
v. Efficiency
30
 vi. Ergonomics
vii. Safety
5.3 Design Alternative
Four alternatives are to be considered from function tree below:

feed processing
machine

power transmissio cutting

n system milling loading seaving
source
roller blade unloading
motor manual hamme
chain r
belt attrition conveyer sieve
gear hopper
engine belt
chute

Figure 5.1: The function decomposition

Few possible combinations
Motor belt hammer blade cutter hopper chute sieve
Motor gear hammer blade cutter hopper chute sieve
Motor chain hammer blade cutter hopper chute sieve
Manual chain roller blade cutter hopper chute sieve
Engine belt attrition blade cutter hopper chute sieve
Engine gear hammer blade cutter hopper chute sieve
From the above combinations the selected best four alternatives are as follows
Alternative A: motorized feed processor with belt drive and hammer miller
Alternative B: motorized feed processor with gear and hammer
Alternative C: manual feed processor with chain drive and roller
Alternative D: engine feed processor with belt drive and attrition
5.4 Determination of the Weight Factor
Judges weighting the factors from 1 to 5, 1 being the minimum weight and 5 the maximum
weight in design consideration. Table 5.2 shows the determination of weighting factors for
each of the seven factors selected

31
 Judges Efficiency Capacity Ergonomic Maintainabilit Durabilit Safety Cost Total
s y y (X)

1 4 4 5 5 5 5 5
2 5 5 4 3 5 5 5
3 3 4 5 4 4 5 5
4 4 3 4 5 3 5 4
5 4 3 5 4 4 4 3
Total 20 26 23 21 21 24 22 ∑150
Weght 0.133 0.127 0.153 0.140 0.140 0.160 0.147
factor
Table 5.1: Weighting factor

5.5 Design Alternatives

5.5.1 Alternative A
Motorized Feed Processor with Belt Drive and Hammer Mill and Blade Cutter
Working Principle
The milling process is accomplished by striking the grain by rotating hammer, the striking of
grains with rotating hammer it causes the grain to break into small particle, the hammers are
hanged on the pins which is pinned on the discs, the discs are welded on the shaft which is
connected with the pulley which is connected with the motor by belts. The mechanism of
machine consists of a motor that transmits power to the belt drive that is connected with the
shaft that are used to process the feed. The shaft has discs which having hanging hammers
that are used in the process of milling the feed also the shaft is welded with blades for cutting
the grass fibers, during grass cutting the sieve is removed.
Advantages of the machine
i. Can be used over long distance due to belt drive
ii. High loading capacity
iii. High production rate
iv. Low running cost
v. Simple in operation
vi. Less man power is required
Disadvantage

32
 i. Too much friction is generated
ii. Noisy operation
iii. Slippage due to insufficient due to insufficient belt tension or overload
iv. Initial cost is relatively high

Figure 5.2: Motorized Feed Processor with Belt and Hammer Mill
Table 5.2; Marks and average for an Alternative A
Judges Efficiency Capacity Ergonomic Maintainabilit Durabilit Safety Cos
s y y t

1 5 5 5 5 5 5 4
2 5 5 5 5 4 5 5
3 5 5 5 5 5 4 5
4 5 5 5 5 4 5 4
5 5 5 5 4 3 4 4
Averag 5 5 5 4.8 4.2 4.6 4.4
e

5.5.2 Alternative B
Motorized Feed Processor with Gear and Hammer and Blade
Working principle
The milling process is accomplished by striking the grain by rotating hammer, the striking of
grains with rotating hammer it causes the grain to break into small particle, the hammers are

33
 hanged on the pins which is pinned on the discs, the discs are welded on the shaft, the shaft is
connected with driven gear which mesh with drive gear from the motor.
The power is transmitted from the motor and goes to the gear which then transmits the drive
to the shaft that is joined with the hammers. The shaft then rotates with a given angular speed
which will allow the hammers to generate required toque for milling the feed and after that
the feed is moved to the blade which also rotates and causes the blade to cut the grass into
small pieces, during grass cutting sieve is removed.
Advantage
I. High torque multiplication
II. No slip hence the machine has constant speed ratio
III. Use small space

Disadvantage
I. It is not safe to operator
II. Costly than belt drive
III. It is not safe to operator Milling hammer Blade cutter

bearing
Feed hopper for grains

shaft
Feed hopper for
grass

Gears sieve
mesh

chute

motor

Figure 5.3: motorized feed processor with gear and hammer

34
 Table 5.3: Marks and average for an Alternative B
Judges Efficiency Capacity Ergonomics Maintainabilit Durability Safety Cost
y

1 5 5 5 5 4 5 5
2 5 5 4 5 5 5 5
3 4 4 4 4 3 5 5
4 4 3 3 5 4 4 5
5 5 4 5 4 4 4 5
Average 4.6 4.2 4.2 4.6 4 4.8 5

5.5.3 Alternative c
Manual Feed Processor with Chain and Roller
Working principle
The machine is used to mill and cut with a manual source of power that is transmitted with a
chain drive that will help to multiply the toque so as to enable the process of milling to take
place easily with the required mechanical advantage therefore the milling process unlike the
other two alternatives does not require electric power. Also the rollers are used as the millers
and the blade which are welded on the shaft are used to cut the feed, during grass cutting the
sieve is removed in order to allow easier flow of cut grass from the cutting chamber to the
chute.
Advantages
i. No need for electricity
ii. No slip hence constant speed ratio
iii. Transmission of power is affordable compared to belt drive
iv. The roller milling is much cheaper than hammer.
Disadvantages
i. Cause fatigue

35
 ii. None ergonomically
iii. Lower power due to manual operation resulting to poor milling

Figure 5.4: Manual Feed Processor with Chain and Roller

Table 5.4: Marks and average for an Alternative C

Judges Efficiency Capacity Ergonomic Maintainabilit Durabilit Safety Cos
s y y t

1 5 5 5 5 5 5 4
2 4 5 5 5 4 5 5
3 5 5 5 5 3 4 5
4 5 4 5 3 4 5 3
5 5 3 4 4 3 4 3
Averag 4.8 4.4 4.8 4.4 3.8 4.6 4
e

5.5.4 Alternative D
Engine Operated Feed Processor with Belt Drive and Attrition
Working principle
The power is transmitted by the engine using a belt drive as the source of power then the feed
is milled by using the attrition which is rotating with the drive from the belt having the

36
 required torque and power and the cutting is done by the welded blade which have the
required orientation and sharpness to cut grass fibers.
Advantages
i. It has a stronger joint than hammers
ii. It is less noisy compared to hammer
Disadvantages
i. Lower efficiency compared to motorized
ii. Purchasing cost is high
iii. Lower capacity of milling due to gap
iv. Maintainability is complex

Figure 5.5: Engine Operated Feed Processor with Belt Drive and Attrition

Table 5.5: Shows marks and average of Alternative D

Judges Efficiency Capacit Ergonomic Maintainabilit Durabilit Safety Cos
y s y y t

1 5 3 3 3 3 4 2
2 5 3 4 5 2 3 4
3 4 4 2 3 4 3 4

37
 4 4 4 4 5 2 4 2
5 5 5 5 4 3 3 3
Average 4.6 3.6 3.6 4 2.8 3.4 3

Table below, shows the weighting factors, weight and score of each alternative according to
the five judges as indicated in each table of the three Alternatives.
Table 5.6: Weighting factors, weight and score

Maintainability
Alternatives

Ergonomics

Rank order
Total score
Durability
Efficiency

Capacity

Safety

Cost
Weighting 0.133 0.127 0.153 0.140 0.140 0.160 0.147
Factors
A Score 5 5 5 4.8 4.2 4.6 4.4 1
Weight 0.665 0.635 0.765 0.672 0.588 0.736 0.647 4.708
B Score 4.6 4.2 4.2 4.6 4 4.8 5 2
Weight 0.612 0.533 0.643 0.644 0.560 0.768 0.735 4.495
C Score 4.8 4.4 4.8 4.4 3.8 4.6 4 3
Weight 0.638 0.559 0.734 0.616 0.532 0.736 0.588 4.403
D 4
Score 4.6 3.6 3.6 4 2.8 3.4 3
Weight 0.612 0.457 0.551 0.560 0.392 0.544 0.441 3.557

Note: Weight = Score x Weighting factor

From the table above, the best alternative is one with highest weight, and that’s ranked as
number 1. Thus, the best alternative is an ALTERNATIVE A. which is motorized feed
processor with belt drive and hammer mill
5.6 DESIGN CALCULATION
Having selected the best alternative;(i.e. Alternative A), It is necessary to perform design
calculations for proper selection of the sizes of the various components of this machine. The
designing machine consists of the following components namely:

1. Motor

38
 2. Belt drive
3. Shaft
4. Flat bars, hammers and pins
5. Hopper
6. Chutes.
7. Frame of the machine
8. Knife
9. Bearings
10. fasteners
5.6.1 Main Specification
There are many cereal products which are used by livestock for feeding such as corn, wheat,
sorghum, forage and maize. Among of these cereals maize grains are very hard compare to
other, therefore the design will consider on maize.
The selection of the motor depends on the work to be performed in the designing machine.

 Capacity rate of the machine- 600 to 1000kg/hour

 Feed per cycle- 7 maize cobs/cycle
 Mass of one maize cob=0.025kg
 Feed per cycle-7 cobs/cycle =7x0.025kg=0.175kg/cycle
 Capacity rate=800kg/hour =10kg/min
Therefore, the motor recommended for this capacity is of Power rating of 3hp and rotational
speed of 1470rev/min.

Then; the exactly rotational speed of the shaft will be=400rev/min

Therefore; the major technical specifications of the machine are as follows:

 Power requirement- 3hp

 Speed of the motor-1470rev/min
 Rotation speed of the shaft with bitters-400rev/min
 Types of the bearings- deep groove ball bearing
 Drive-Vee belt
 Construction-Fabricated(bolted/welded)
 Material-Steel (mild steel)
 Discharging –Gravity
 Feeding-Gravity

39
  Power source-motor (3hp)
 Shelling capacity rate of the machine-600 to 1000kg/hr.
 Overall size of the machine- 870mm x 400mm x 770mm

5.6.2 Determination of Angular Speed of the Motor

Ѡ1 =2 π N 1……………………………………….……………………….....................(5.1)
2 x ∏ x 1470
Ѡ1 = = 153.9rad/sec
60
5.6.3 Torque Transmitted by Motor.

Power
Tm = ……………………………………………………………………(5.2)
ω1
3 x 1000 x 0.746
Tm = = 14.54Nm
153.9

5.6.4 Belt Selection

The type of belt is chosen by considering the torque of 14.54Nm and to extent the service life
of the belt from appendix A belt table 2, the belt type is A

5.6.5 Determination of Angular Velocity of the Driven Pulley

2∏ N 2
Ѡ2 = ……………………………………………………………… (5.3)
60

2∏ x 400
Ѡ2 = = 41.9rad/sec
60

Therefore, the diameter of the large sheave is given by;

D1 x N 1
D2 = ……………………………………………………..…... (5.4)
N2

60 x 1470
D2 = = 220mm
400

5.6.6 Determination of The Speed Ratio

ω1
r= ……………………………………………………….………...(5.5)
ω2

153.9
= = 3.67
41.9

40
5.6.7 Computation of Belt Speed

D 1 x ω1
V= ………….…………………………………………………... (5.6)
2 x 1000

60 x 153.9
V= = 4.62rad/sec
2 x 1000

5.6.8 Determination of Center Distance Between the Driver and

Driven Pulley
Specify tentatively center distance the following are considered;

Cmin = 0.55(D1 +D2) + h…………………………………………………………. (5.7)

Cmax = 2(D1 + D2) …………………………………………………………………

(5.8)

Where h is the belt thickness. For the belt type A, h =8

Cmin = 0.55 ( 220+60 )+ 8=162 mm

Cmax = 2 ( 220+60 )=560mm

Take the minimum center distance, Cmin = 162mm

5.6.9 Determination of Belt Length

π ( D 2 – D 1)2
L= 2C min + (D2+D1) + …………………………………..………...
2 4 C min
(5.9)

2
π (60−220)
L= 2 x 66 + 2 (60 +220) + = 803.3mm
4 x 162

The standard design length and particulars of the belt table 4 appendix C, is 925mm.

5.6.10 Determination of The Final Center Distance

…………...…………. (5.10)

[ ] √[ { }]
2
π π (220+60) 8 ( 220−60 )
c = 0.25 925− (220+60) + 925− −
2 2 4

C = 516mm

41
 Therefore; the final center distance is C = 516mm

5.6.11 Angle of Wrap

D1−D2
α=¿ sin-1( ) ……………………………………………………………………. (5.11)
2C

220−60
α=¿ sin-1(
2 x 516
) = 0.156

Small angle θ1

θ1= π−2 α .................................................................................................................. (5.12)

θ1= π−2 x 0.156=2.83 rad

large angle θ2

θ2¿ π +2 α ……………………………………………………..…………………. (5.13)

θ2¿ π +2 x 0.156=3.45 rad

5.6.12 Tension On Tight and Slack Side (T1 and T2)

(T1-T2) r2 =Ʈ2 …………………………………………………………...…………. (5.14)

(T1-T2)0.11=53.4

T1-T2=485.45………………………………………………………. (ⅰ)

T1/ T2 = ⅇ
µθcosecβ
…………………………………………………………………. (5.15)
Where
µ-coefficient of friction between belt and pulley, β-groove angle, θ-small value of angle of
wrap

for type A belt µ=0.3, 2β=34֯

T1/ T2= ⅇ0.3x2.83cosec17֯

T1=18.24T2 ……………………………………………………………………(ⅱ)

Substitute equation (ⅱ) into equation (ⅰ)

18.24T2-T2=485.45

T2=28.15N, T1=513.64N

42
Therefore, the tension on the tight side of the belt is 513.64N and the tension on the slack side
is 28.15N

5.6.13 Resultant Force Acting On Driven Pulley Ta

Ta = T1+T2 = 513.49+28.15
Ta=541.64N

5.6.14 Number of Belt

Power transmitted per belt Pd

Pd = (T1-T2)V = ( 513.49−28.15 ) X 4.62

Pd = 2236.9watts

power of driver motor

Number of belt= …………………………………….. (5.16)
power transmitted per belt

2238
=1
22236.9

Factor of safety of belt = 2

number of belt=factor of safety ×obtained belt

¿ 2 ×1=2

Therefore, number of belt is 2

5.6.15 Theoretical Beater Design

the material used for construction of beater bar (flat bar) is mild steel. Beater plate should be
movable so that so that it can be easily break down the grains with centrifugal force. The
clearance between the beater plate and concave sieve is 2 mm so the materials should be
broken and size should be reduced. The dimension of the beater is showed on figure below

43
 figure 5.6; beater bar (flat bar)
5.6.16 Theoretical Design of the Blade
Material used = carbon steel
cutting load per unit width
thickness of theblade= …………………………………. (5.17)
yield strength
200
¿
170
¿ 1.2 mm
Factor of safety = 6.7
thickness of theblade=6.7 ×1.2
thickness of theblade=8 mm
5.6.17 Theoretical The Length of the Cut Pieces
'
πD N
x= …………………………………………………………………....………. (5.18)
NR
Where
X = theoretical length of the cut, mm
D = diameter of feed rolls, mm
'
N = revolution per minute of feed rolls, rpm
N = revolution per minutes of cutting unit, rpm
R = number of blade used
π × 80 ×60
x=
400 ×2
x=18.8 mm
So, theoretical length of cut =18.8mm
5.6.18 Shaft Design

Force acting on the shaft are;

Force due to hammers and pins F1.
Force due flat bars F2.
Force due to knifes F3
Force due to total tension on the belt Ta.
Force due to hammer
F =mg = ρvg……………………………………………………………..…………. (5.19)

44
Where ρ is the density of mild steel which is 7860 kg/m3

figure 5.7: hammer

h = 4mm, b = 28mm, L = 80mm

volume of the hammer v1

v1 = h x b x L ……………………………………………………………………… (5.20)

v1 = 4 x 28 x 80 = 8.96 x10-6mm

Fa = 8.96 x 10-6 x 7860 x 9.81 = 0.69

For 20 hammers

Fa1 = 0.69 x 20 = 13. 82N

Force due to pin

π d2
Fb = x l x ƍ x g ………………………………………………(5.21)
4

45
 Figure 5.8; pin
d=8 mm ,and l=180 mm , material of the pin is mild steel

2
π x8
Fb = x 180 x 7860 x 9.81 = 0.69m3
4

For four pin

Fb1 = 4 x F = o.69 x 4

Fb1 = 2.79N

Force of hammers and pin.

F1 = Fa1 + Fb1 = 13.82 + 2.79

F 1 = 16.61N

Force exerted by 4 flat bars

F 2=¿ 230 ×60 × 8× 7860× 9.81 ×4 × 10-9

F 2=34.07 N

Weight of the blade

F 3=230 ×60 ×6 × 7860× 9.81× 2× 10-9

F 3=12.77 N

Total force F t

F t¿ F 1+ F 2+ F 3 …………………………………………………………………….(5.22)

=16.61+34.07 ×2+12.77

F t = 96.47 N

Shaft Design

Consider the free body diagram (FBD) figure 1 (a) for the shaft as taken from the selected
alternative, let’s find the reaction force (RA and RC) acting on the shaft to be designed;

46
 Figure 5.9; free body diagram

Reaction force Ra and Rc

Sum of upward force must be equal to zero i.e. ∑ F ↑=¿ 0

Ra + Rc = 96.47+ 541.64

Ra + Rc¿ 638.11 N

Sum of moment about point A equal to zero i.e ∑MA = 0

0.3RC = 541.64 × 0.5+96.47 ×0.15

RC = 950.97N

RA = -312.86N

Bending moment and shear force diagram

47
 figure 5.10; (a) FBD, (b) SFD, (c) BMD
Shear forces

FD = 541.64N

FC = 541.64 – 950.97

FC = -312.86N

Bending moment

∑MA = 0, ∑MD = 0

∑MC = 541.64 × 0.2=108.33 Nm

∑MB = 541.64 × 0.35−950.97 × 0.15=46.93 Nm

Now, the permissible shear stress of the shaft is given as;

τ all = 0.3 S yt

τ all = 0.18 Sut [Bhandar, 1994]

48
For the selected material of Shaft i.e. mild steel

The ultimate tensile strength, Sut = 560N/mm2 to 670N/mm2

The Yield stress, S yt = 322N/mm2

Let Sut = 615N/mm2

Therefore, the allowable shear stress ( τ all) is;

τ all = 0.3 x S yt ……………………………………………….……………………….(5.23)

τ all = 0.3 x 322 = 96.6N/mm2

Also,

τ all = 0.18 x Sut ………………………………………………………...……………(5.24)

τ all = 0.18 x 615 = 110.7N/mm2

We take the smallest one since the shaft is keyed, then 25% of the τ allis reduced therefore
25
from τ allis taken 96.6 x = 72.45N/mm2
100

τ all = 72.45N/mm2

Considering the Shock and fatigue factors;

The load is gradually applied or steady load to the shaft. From appendix D, table 5

Let, Kt = Shock and fatigue factors for torque.

Km = Shock and fatigue factor for bending moment.

Kt is taken to be 1.0 since the load is gradually applied.

Km is taken to be 1.5 since the load is gradually applied.

5.6.19 Determination of The Shaft Diameter On Basis of Torque

On the basis of the torque, the equivalent twisting moment;

T e = √( K m × M BM )2 +¿ ¿……………………………………………….…... (5.25)

T e = √(1.5 x 108.33)2 +¿ ¿

T e = 171.15Nm

49
Where; T e is twisting moment of the shaft.

T is torque transmitted by shaft.

Also, Twisting Moment;

π
Te =
32
x τ all x d
3
………………………………………………(5.26)

π 3
171150 = x 72.45 x d
16

16 x 303,005.942
3
d = =12031.191mm 3
π x 72.45

d = 22.91mm

factor of safety of shaft = 1

diameter of shaft = 1 x d

diameter of shaft = 22.91 x 1 =22.91mm

5.6.20 Determination of Shaft Diameter On Basis of Bending Moment

1
On basis of equivalent bending moment, M e =
2
[ ( M BM ) +T e ]…………….…...... (5.27)
1
Me =
2
[ ( 1.5 x 108.328 ) +171.15 ]

M e= 166.821Nm

π 3
Also; bending moment, M e = x τ all x d ……………………..…….……….. (5.28)
2

π 3
166821 = x 72.45 x d
32

3 32 x 166821
d= =23453.7578 mm3
π x 72.45

d= 28.62mm

diameter of shaft =d x factor of safety of shaft

= 28.62 x 1 = 28.62mm

50
Therefore, for design we taking the larger of the two values, d = 28.62≈30mm.

The standard diameter size for transmission shaft starts with 25mm to 30mm and above.
Therefore, the shaft diameter is taken to be 30mm [Nagpal, 1991].

5.6.21 Key Design

A key is a machine element which is used to secure rotating elements such as pulleys gears
etc.

In this design the square sunk key is selected. See appendix C

Figure 5.11; key

Square sunk key

Where: L = Length of key

b = Width of key

t = Height of key

Width and Height of key

Since the key is square, its width and height are equal and is quarter of shaft diameter

Thus: b= t =d/4 ………………………………………………………………………… (5.29)

=30/4 = 7.5mm say 8mm

Length of key: L

L = 1.5d ……………………………………………………………………………… (5.30)

= 1.5x30 = 45mm

Force acting on the key: F

2T
F¿ ………………………………………………………………………………..(5.31)
d

2× 53430
¿ =3562 N
30

51
Where:T = Transmitted torque\

d = Shaft diameter

F = Tangential force

5.6.22 Shear Stress and Crushing Stress

𝜏s = F/bL ………………………………………………………………………………...
(5.32)

3562
¿ =¿
8 ×45

𝜏c = 2T/Lx br ……………………………………………………………………………. (5.33)

2 ×53430
= =19.79 N /mm2
15× 45 × 8

Since shear stress and crushing stress are less than allowable shear stress therefore the key
design is safe.

5.9 BEARING SELECTION

5.9.1 Determination of Radial and Axial Forces Acting On the Bearing
Bearing must be selected based on its load carrying capacity, life expectancy and reliability
(PSG Tech 1989). The equivalent dynamic load of the bearing is expressed as;

P = XF r +YF a………………………………………………………………... (5.34)

Where;

P = Equivalent dynamic load (N)

Fr = Radial load (N)

Fa = Axial or thrust load (N)

X = Radial factor

Y = Thrust factor

From the previous calculation of the reactions on bearing;

RA = FRA = -312.86N

52
 RC = FRC = 950.97N

Since, there is no axial load, i.e. Fa = 0

Therefore, Radial load at bearing A = -312.86N

Radial load at bearing C = 950.97 N

The diameter of the shaft where the bearing has to be fitted = 30mm (Calculated)

Determination of the value of radial factor from the manufacture catalogue was found that;
for single row deep groove ball bearing, X = 1 and Y = 0

From equation (5.34)

The equivalent dynamic load at B is;

PA = XFRA (Since Fa = 0)

PA = 1 x -312.86 = -312.86N

The equivalent dynamic load at C is;

PC = XFRC

PC = 1 x 950.97 = 950.97N

5.9.2 Determination of Expected Bearing Life

By assuming that, the machine is working for 8 hours of service per day; then the
recommended bearing life is 20000 hours. [Bhandar, 1994]. The bearing life is expressed as;

60 N 1 Lh
L= 6 ……………………………………………………… (5.35)
10

Where;

L = Bearing life (in million revolution)

N1 = Speed of rotation of the rotor (rpm)

Lh = Bearing life (hours)

60 x 400 x 20000
L= = 480 million revolution
10 6

From the load –life relationship as expressed below

53
L = (C/P) j …………………………………………………………………. (5.36)

Where;

C = Dynamic load capacity (N)

P = Equivalent dynamic load (N)

J = 3 (for ball bearings)

Therefore, C = PL 1/ j

1
For bearing A, C = P x L1 / j=−312.86 N x 480 3 =−2449.6 N
A

For bearing C, C = PC x L1/ j =950.97 N x 4801 /3 =7445.8 N

From the catalogue of bearing selection under the deep groove ball bearing with shaft
diameter of 30mm, it is found that the dynamic load capacity equivalent to the values
obtained above is 7280N and bearing designation of 206. [SKF General Catalogue, 1991]

5:15 Design of feeding hopper

The shape of the hopper is rectangular which is reduced at the bottom. Material used to make
the hopper is mild steel sheet of 3mm thick. This selection is due to the fact that the
recommended material is cheap and easy machinable. The size of the hopper is 180mm x
70mm x 300mm.More dimension are shown on the detail drawing,

5.12. DESIGN OF DISCHARGE HOPER

The shape of the feed hopper is tapered downside and rectangular from top; the required
material used to make the hopper is mild steel sheet of 1.5mm thick. This selection is due to
the fact that the recommended material to be used is steel (mild steel or manganese steel)
which has good resistance to wear and tear capability, and it is easy machinable.

5.13. DESIGN OF THE FRAME

The frame is manufactured by using Angle line bar of high carbon steel with dimension of
40mm x 40mm x 400mm. The height of the frame is 770mm.The joining of the different
joints is by welding. The physical layout of the frame and the manner of fabrication can be
seen in the assemble drawing, appendix M. The figure below is the isometric view of a frame

54
5.15 MANUFACTURING PROCESS OF MODIFIED FEED PROCESSING
MACHINE FOR HUSBANDRY
Table 5.7: Operation sequence of manufacturing a modified feed processing machine for
husbandry
OPERATRION OPERATION MACHINE TOOLING TIME
No. SPENT

1 Cutting and welding Hack saw, welding Hacksaw blade, 8hrs

the angle iron of machine with its tape measure,
40mm to make a accessories and welding
frame of the machine machine with
its accessories

2 Turning to Φ30mm a Lathe machine, Turning tool, 5hrs

mild steel shaft
500mm long, with
steps at the ends to
Φ25mm one end at
200mm other at
44mm

3 Cutting keyway on Milling machine Milling cutter 4hrs

the step of 200mm
ling at Φ25mm with
dimensions of

4 Cutting a plate of Hand grinder Cutting disc 2hrs

thickness 1.5 mm
with dimensions
500mm x 605mm

5 Cutting and bending Hand grinder, Cutting disc, 2hrs

a plate to make a manual bending Shear blades
semicircle with machine

55
 diameter of 320mm
and 605mm long

6 Cutting taper plate of Hand grinder, Cutting disc, 3hrs

length 350mm and welding machine welding rods
tapered width from and its accessories
300mm to 120 at the
end. And welding it
to make the hoper

7 Cutting metal of Hand grinder, Hacksaw blade, 3hrs

439×605mm,bendin Drilling machine, drill bits,
g drilling and milling and milling tool and
grinding them to grinding machines grinding disk
make the sieve for
the

8 Assembling the Spraying machine Ring spanner, 8hrs

machine, and finally fix spanner,
spraying the machine pliers and Allan
with paint. key

56
 CHAPTER SIX
CONCLUSION AND RECOMMENDATION
6.1 Conclusion
For the project to be feasible it has passed through various procedures up to the selection of
the best alternative. Literature review has shown the technology regarding the existing feed
processing technology in terms of strength and their weakness and data collection assist to
look for product design specification (PDS) that will meet need for the society, in term of
capacity, cost, durability and working environments, use ergonomics, etc. Modification of the
machine has to be done to bridge the gap that exists in current feed processing technology
considering the data (design specification) collected through observation and interview from
the sites of study. These data were very useful during the selection of the best alternative, on
selection of optimal alternative different factors such as production cost, durability, capacity,
efficiency, ergonomics and safety were critically analyzed from which the optimum design
was selected, where motorized feed processing with belt drive and hammer miller selected as
the best alternative.

RECOMMENDATION
In order to make these power operated grass cutter and milling machine more versatile and
perfect in all respect for commercialization the following suggestion are made for future
work
1. Exhaustive trials of the newly developed power operated chaff cutter and grains milling
should be carried out for all types of wet and dry fodder crops for better evaluation.
2. Give desired degree angle to blade to the horizontal to reduce load and at the same time
cutting by shearing and impact action.

57
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Kalpakjian, s. & Schmid, S., 2005. Manufacturing, Engineering and Technology. 5th editin
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lazor, E. B., 2013. Development of low cost machine for improvement of sorgum machine.
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machineries, k. a., 2018. [Online]
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Muheza (2018) Hatibu Mohamed.

nwaigwe, I. M., p. F. & . & Abu, k., 2003. Pelleting technology. 2nd ed ed. s.l.:Abuja:
ochwukwu General supply.

Peterson, 1984. lawn mover safety and repair. s.l.:s.n.

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[Accessed 25 12 2018].

59
PROJECT COST ESTIMATION
There are three cost that have been considered under this cost estimate, these cost include
i. Material cost.
ii. Labour cost.
iii. Machining cost.
iv. Overall cost.

MATERIAL COST
The considered cost in this design is roughly estimated based on construction of the whole
machine. The part like belt, bearing, bolt and nut, washers, pulleys, angle iron and mild sheet
should be purchased from dealers and manufacturers according to the design specifications.
The material cost is approximately based on the datasheet and the cost of the material from
the local markets.
Table 1: project cost estimation sheet
S/N Description Quantity Price (Tshs) Subtotal
1 Angle iron 8 @3400/= 27200/=
30mmx30mmx3mm
2 Mild steel sheet 1 @20000/= 20000/=
1000x500x3mm
3 Bolts and nut 14 @500/= 7000/=
M12x20
4 v-belts 2 @6000/= 12000/=
5 pulleys 2 @20000/= 40000/=
6 Bearings 3 @15000/= 45000/=
7 sieve 1 @10000/= 10000/=
8 Shaft 1 @25000/= 25000/=
∅ 40 mm ×600 mm
9 Flat bar 800x30x8 1 @8000/= 8000/=

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 10 Electric motor (3hp 1 @50000/= 50000/=
1 phase)
11 Welding road 3kg @4000/= 12000/=
12 Blade 250x6 2 @10000/= 20000/=
13 paint 2litre @15000/= 30000/=
14 total 306200/=
LABOR COST
The labor payment is calculated as;
labor cost =30 % of material cost
30 ×306200
labor cost =
100
Labor cost is T.sh 91900/=

FABRICATION AND MACHINING COST

Fabrication and machining cost as taken from the same workshop, payment estimates is
calculated as;
Fabrication and machining cost = 20% of material cost
20× 306200
=
100
Fabrication and machining cost is T.sh 61200/=
Overall cost
The overall cost is taken as 40% of the labour cost plus machining and fabrication cost.
40 ×(91900+61200)
Overall cost =
100
Overall cost = 61200/=
Therefore, overall cost is T.sh 61200/=
TOTAL COST
The total cost of feed processing machine for husbandry is taken as the summation of
material cost, labour cost, fabrication and machining cost plus overall cost
Total cost = material cost + labour cost + fabrication and machining cost + overall cost
= 306200 + 91900 + 61200 + 61200
Total cost = 520500
The total cost is T.sh 520500/=

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 APPENDIX A
Table 2; dimensions of standard v-belts according to IS: 2494 – 1974

APPENDIX B
Table 3; Dimensions of standard V-grooved pulleys according to IS: 2494 – 1974

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 APPENDIX C
Table 4; Standard pitch lengths of V-belts according to IS: 2494 – 1974

APPENDIX D
Table 5; Recommended value for km and kt

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