Jimma University

JIMMA UNIVERSITY
JIMMA INSTITUTE OF TECHNOLOGY

FACULTY OF MECHANICAL ENGINEERING
DESIGN OF SMALL-SCALE SUGARCANE HARVESTING MACHINE
Name ID NO
MOSISA TASGARA RU 3265/11
NATANEM DAMENE RU 4057/11
NIMONA DAMENE RU 4064/11
SEGNI MERZE RU 3485/11
TAMIRU FUFA RU 3812/11
Submission Date June 14, 2023

Jimma, Ethiopia
Final year project 2023
Declaration
We hereby declare that the final project titled DESIGN OF SMALL-SCALE SUGARCANE
HARVESTING MACHINE submitted by us is based on actual and original work carried out by
us. Any reference to work done by any other person or institution or any material obtained from
other sources has been duly cited and referenced.
Name Signature Date
MOSISA TASGARA
NATANEM DAMENE
NIMONA DAMENE
SEGNI MERZE
TAMIRU FUFA
This BSc. Project has been submitted for examination with my approval as Project advisor.
Name
Signature Date
i
Jimma University JIT, Faculty of Mechanical Engineering
Acknowledgment
First of all, we would like to thank the Almighty God for giving us the strength to carry out this
project and for all his good deeds. Next, we would like to extend our special thanks to Mr.
Tarekegn Limore our advisor for generously sharing wisdom, and thoughtful advice, and for his
assistance, evaluation, supervision, and consultation on the completion of this project paper. Our
appreciation goes to all academic and administrative staff of the mechanical design and
manufacturing engineering department who have contributed to this work’s success. Finally, we
would like to pass our great gratitude for our campus, Jimma Institute of Technology, for all
provisions and life enjoyed in our five years of life in the campus.
ii
Abstract
Sugarcane is a vital crop in Ethiopia, but its harvesting is challenging and inefficient. Manual
harvesting with machetes is labor-intensive, time-consuming, and hazardous for workers.
Imported machines are expensive and unsuitable for small-scale farmers who have limited
resources and land. Therefore, there is a need for a simple and effective small-scale sugarcane
harvesting machine that can address these issues and improve the productivity and profitability
of sugarcane production in Ethiopia. This project aims to design such a machine that can cut
sugarcane stalks with less labor, time, and risk. The machine consists of a two-stage gearbox, a
V-belt drive, a bevel gear mechanism, and a cutter blade. The design parameters of the machine
are based on optimal values such as row spacing, sugarcane length, engine power, and velocity
ratio. The row spacing is 0.75 m, the sugarcane length is 2000 mm, the engine power is 6.25 HP,
and the velocity ratio is 2:1. The design process involves modeling the machine components in
CAD software (SolidWorks) and creating a functional 3D model of the machine.
Keywords: small-scale sugarcane harvesting machine, gearbox, V-belt drive, bevel gear
mechanism, cutter blade, CAD modeling.
iii
Table of Contents
Declaration ....................................................................................................................................... i
Acknowledgment ............................................................................................................................ ii
Abstract .......................................................................................................................................... iii
List of figures ................................................................................................................................ vii
List of tables ................................................................................................................................... ix
Nomenclature .................................................................................................................................. x
CHAPTER ONE ............................................................................................................................. 1
1 INTRODUCTION .................................................................................................................... 1
1.1 Background ........................................................................................................................... 1
1.2 Problem statement ................................................................................................................. 3
1.3 Objectives .............................................................................................................................. 4
1.4 Scope of the project ............................................................................................................... 4
1.5 Significance ........................................................................................................................... 5
1.6 Limitation .............................................................................................................................. 5
CHAPTER TWO ............................................................................................................................ 6
2 LITERATURE REVIEW ......................................................................................................... 6
2.1 The overview of sugarcane harvesting .................................................................................. 6
2.2 Method of harvesting and previous works ............................................................................ 6
2.2.1 Equipment of full mechanization sugarcane harvesting .................................................... 8
2.2.2 Equipment of semi mechanization sugarcane harvesting ................................................ 10
2.3 literature gap ........................................................................................................................ 13
CHAPTER THREE ...................................................................................................................... 14
3 METHODOLOGY AND MATERIAL SELECTION ........................................................... 14
iv
3.1 Methodology ....................................................................................................................... 14
3.2 Material selection ................................................................................................................ 16
3.3 Working principle ............................................................................................................... 19
CHAPTER FOUR ......................................................................................................................... 20
4. DESIGN ANALYSIS ........................................................................................................... 20
4.1 Design consideration ........................................................................................................... 20
4.2 Design of pulley and V belt................................................................................................. 21
4.3 Design of shaft .................................................................................................................... 28
4.4 Design of cutter (bottom cutter) .......................................................................................... 35
4.5 Design of upper cutter ......................................................................................................... 36
4.6 Design of keys and keyways ............................................................................................... 37
4.7 Bearing Selection ................................................................................................................ 39
4.8 Design of bolt and nut ......................................................................................................... 44
4.9 Design of bevel gear ............................................................................................................ 46
4.10 Design of gearbox ............................................................................................................. 54
4.11 Design of chain drive ........................................................................................................ 56
4.12 Wheel selection ................................................................................................................. 61
4.13 Ground wheel .................................................................................................................... 62
4.14 Frame................................................................................................................................. 63
CHAPTER FIVE .......................................................................................................................... 65
5.1 RESULT AND DISCUSSION............................................................................................ 65
5.2 SIMULATION RESULT .................................................................................................... 68
5.2.1 Bearing Simulation Analysis ........................................................................................ 68
5.2.2 Bevel Gear Simulation Analysis................................................................................... 71
v
5.2.3 Frame Simulation Analysis .......................................................................................... 74
CONCLUSION ............................................................................................................................. 78
RECOMMENDATION ................................................................................................................ 79
References ..................................................................................................................................... 80
Appendix ....................................................................................................................................... 83
vi
List of figures
Figure 2-0-1;Infield sugar cane harvesting systems [12] ............................................................................. 7
Figure 2-0-2 Self-propelled whole stalk sugarcane harvester [17] ............................................................... 9
Figure 2-0-3Chopper harvester (sugarcane combine) [19] ......................................................................... 10
Figure 2-0-4 VICRO South African made sugarcane harvester[25] ........................................................... 12
Figure 2-0-5 Walking type sugarcane harvesters in operation [27] ............................................................ 13
Figure 3-0-1; flow chart of methodology .................................................................................................... 14
Figure 3-0-2 harvesting sugar cane on a plantation in Malawi, Africa Stock Photo [28] ........................... 15
Figure 3-0-3; 3D model of small-scale sugarcane harvesting machine ..................................................... 19
Figure 4-0-1 Pulley connected whith shaft ........................................................................................... 28
Figure 4-0-2 Reaction force of horizontal shaft .......................................................................................... 31
Figure 4-0-3 Reaction force of vertical shaft .............................................................................................. 33
Figure 4-0-4 Bending moment diagram ...................................................................................................... 34
Figure 4-0-5; standard designations of ball bearings[33] ........................................................................... 41
Figure 4-0-6 bearing connected with shaft ................................................................................................. 44
Figure 4-0-7 Mitre gears[33] ...................................................................................................................... 47
Figure 4-0-8 Bevel Gear ............................................................................................................................ 53
Figure 4-0-9 wheel ...................................................................................................................................... 61
Figure 4-10; frame ...................................................................................................................................... 63
Figure 5-0-1 bearing -Stress-Stress ............................................................................................................. 68
Figure 5-0-2 bearing -Displacement-Displacement .................................................................................... 69
Figure 5-0-3 bearing-Strain-Strain .............................................................................................................. 70
Figure 5-0-4 Bevel Gear Stress-Stress ........................................................................................................ 71
Figure 5-0-5 Bevel Gear-Displacement-Displacement ............................................................................... 72
vii
Figure 5-0-6 Bevel Gear -Strain-Strain ....................................................................................................... 73
Figure 5-0-7; frame-Static 2-Stress-Stress1 ................................................................................................ 74
Figure 5-0-8; frame-Static 2-Displacement-Displacement1 ....................................................................... 75
Figure 5-0-9 frame-Static 2-Strain-Strain1 ................................................................................................. 76
viii
List of tables
Table 4-1 Table of reduction of gear box[34] ............................................................................................ 54
Table 5-0-1; Cost analysis .......................................................................................................................... 77
Table A-1 dimensions of standard v-belts according to IS:2494-1974 ....................................................... 83
Table A-2 standard pitch lengths of v-belts according to IS:2494-1974 .................................................... 83
Table A-3 density of belt materials ............................................................................................................. 84
Table A-4 Coefficient of friction between belt and pulley ......................................................................... 84
Table A-5 Recommended value for Km and Kr ......................................................................................... 84
Table A-6 Values of factor of safety ........................................................................................................... 85
Table A-7 Design dimensions of screw threads, bolts and nuts according to IS:4218 ............................... 85
Table A-8 Dimensions of standard v-grooved pulleys according to IS:2494-1974 .................................... 86
Table A-9 characteristics of roller chains according to IS:2403-1991........................................................ 87
Table A-10 power rating (in kw) of simple roller chain ............................................................................ 87
Table A-11 life of bearing and principal dimensions for radial ball bearings ............................................ 88
ix
Nomenclature
𝐾𝐶 = centrifugal tension factor 𝑦𝑐 =tooth form factor
𝑃𝐷 = Design Power 𝑅𝑃 = rated power
𝑆𝑓 = Service factor 𝐾1 = steady and continuous move
𝐷=diameter 𝑀 = mass
𝑁=speed 𝐴 = area
𝑇1 = tension of tight side 𝐿 = length
𝑇2 = tension of slack side Þ = density
𝑉𝑝 = pitch line velocity 𝐵 = face width
𝜎𝐶 = Allowable static stress
τ𝑢 = Ultimate shear strength
𝜎𝑢 = Ultimate tensile strength
d= diameter of shaft
𝑑𝑐 = Root or core diameter of the thread, and
𝜎𝑡 = Permissible tensile stress
𝜃𝑃1 = pitch angle for the pinion
𝜃𝑃1 = pitch angle for the gear
m= module
𝑇𝐺 = teeth of gear
𝑇𝑃 = teeth of pinion
𝐷𝑃 = diameter of pinion
𝐷𝐺 =diameter of gear
x
CHAPTER ONE
1 INTRODUCTION
1.1 Background
Sugar production is a vital industry that has been around for centuries. It is a process that
involves the extraction of sugar from sugarcane, a tall perennial grass that grows in tropical and
subtropical regions. Sugarcane is one of the most important crops in the world, and it is grown in
over 100 countries. The process of harvesting sugarcane and turning it into sugar involves
several steps, including planting, growing, harvesting, milling, refining, and packaging. The first
step in sugar production is planting sugarcane. Sugarcane is typically planted in rows using
cuttings from mature plants. These cuttings are called "setts" and are planted in soil that has been
prepared with fertilizer and other nutrients. Once planted, the sugarcane begins to grow rapidly
and can reach heights of up to 20 feet. After several months of growth, the sugarcane is ready for
harvesting. Harvesting sugarcane involves cutting down the stalks using machetes or specialized
machinery. The stalks are then transported to a mill where they are crushed to extract the
juice[1]. Sugar production is an important industry that involves several steps including planting,
growing, harvesting, milling, refining, and packaging. Sugarcane is a vital crop that provides
jobs for millions of people around the world and contributes significantly to global economies.
The process of sugar production has evolved, with new technologies and techniques being
developed to improve efficiency and reduce waste. Despite the challenges faced by the industry,
sugar production remains a vital part of our daily lives and will continue to be so for many years
to come[2].
Sugarcane plays a significant role in Ethiopian socioeconomic. Sugar and its byproduct are used
for local consumption and export. The industry created job opportunities for a large number of
people. Today in the country sugar consumption outstrips its production. Sugar Corporation of
Ethiopia currently administers six sugar factories: Wonji-Shoa, Metahara, Finchaa, Tendaho,
Arjo-dedessa, and Kessem, and nine sugar development projects at Kuraz, Tana Beles, and
Welkayit. Sugarcane plantations are expanding with current area coverage of 98,986 hectares
and production of 400,000 tons of sugar and 25,388m3 of ethanol per annum[3]. Sugarcane
production has a history of six decades, sugarcane had been cultivated in Ethiopia since the 16th
century. According to the report by the central statistics agency (CSA) currently, sugarcane is
1
produced in about 31,236.81ha with 1,565,060.00 holdings in different parts of the country but
the production is not usually used for industrial purposes. It is noticeably used for making
confectioneries, household consumption (chewing), selling for immediate cash, and feeding
livestock. In some areas, sugarcane is used to prepare a local beverage called “Karibo” mainly
preferred by Muslim communities, while in others the leaves are used for thatching and as
firewood[4].
The sugar industry of Ethiopia is so far dependent on the introduction of exotic varieties which
are not suitably adapted to various agroecologist and local growing conditions. In light of the
rapidly increasing commercial sugarcane plantation areas in the country, the demand for
improved varieties that suit various agroecologist is increasing. Under such situations, there will
be a continuous demand for broad genetic base sugarcane varieties that are high yielding and
stable under abiotic and biotic stresses. Therefore, the industry is currently launching the
breeding program, which is long overdue, to produce its improved varieties[5].
Agriculture in Ethiopia has experienced significant difficulties including a lack of agricultural

labor, not only during the busiest times of the year but also during off-peak periods, and the
existing harvester was an expensive, export model. Agricultural harvesting takes more time and
requires more manpower, and money than any other process[6]. The harvesting process and
gathering mature crops from the field is the process of harvesting. A harvester is a tool used to
collect crops. There are several different types of harvesting equipment on the market, including
paddy harvesters, tea harvesters, potato harvesters, wheat harvesters, and sugarcane harvesters,
all of which are only available on a limited scale. A piece of agricultural equipment called a
sugarcane harvester is used to harvest and refine sugarcane. Hardy sugar cane is grown in
tropical and subtropical areas for its sucrose content as well as for its byproducts, including
molasses and bagasse (the waste fibrous residue). The plant forms clumps of cylindrical stalks
that range in diameter from 1.25 to 7.25 cm and grow to a height of 6 to 7 m. Cane stalks grow
straight up until they are too hefty to support themselves. After then, it lies on its side and keeps
growing upward. As a result, a mature cane field forms a mesh pattern by piling itself on top of
itself. The sap used to make sugar is found in the stalks of the sugar cane plant[7].
Many problems that arise during the cutting process are difficult to resolve. This machine's
design is straightforward to use. To save time and effort, we are designing the sugarcane-cutting
2
machine in this way. We use this machine to cut sugar cane in sugar cane farms. This cutting
device is simple to use and can be handled by anyone in any working environment; no skilled
workers are required to operate this device.
1.2 Problem statement
A great deal of harm in areas where hand harvesting has become usual is caused by machetes.
These wounds can be anything from minor cuts to body part amputations. The machete is also
the tool that the less experienced workers on the farm or plantation use the most frequently.
Maintaining the machete's edge helps prevent injuries because a sharp machete requires less
force from the user and allows for better control. Working with a cane can also easily result in
cuts and damage to the eyes. When the harvesters are often forced to sit or bend over, they use
severe back pain and arms and hands and arms and hands and hands and money. It reduces
unconditioned crop breakage and crop loss during harvest. Large-hectare farming requires many
daily databases and is costly and lack of labor causes delays in the harvesting season.
Since cane is cultivated in tropical and subtropical regions; thus, workers must be aware of heat-
related health issues. The use of the required protective clothes can make this worse. These areas
also receive a lot of sun exposure, which increases the risk of developing different kinds of skin
cancer. Sun exposure needs to be limited or protected against with precautions. Chemicals such
as pesticides and other substances can pose hazardous dangers that can result in poisoning when
ingested or inhaled. This project is a result of the agriculture industry’s need, by developing a
sugarcane-cutting or harvesting machine to reduce labor costs as compared to manual operation.
Also, consumed less time as compared to the manual system and it will be safe.
3
1.3 Objectives
General objective
The general objective of this project is to design a small-scale sugarcane harvesting machine.
Specific objective
The specific objectives of this project are:
➢ To design all the components of a small-scale sugarcane harvesting machine, such as

pulleys, V-belts, shafts, bolts, nuts, gearboxes, sprockets, chains, cutter blades, keys, and
keyways.
➢ To select proper engines and materials for small-scale harvesting machines.
➢ To model 3D of a small-scale sugarcane harvesting Machine by using CAD software.
1.4 Scope of the project
The scope of this project work is designing a small-scale sugarcane harvesting machine starting
from design analysis of the parts such as pulleys, V-belts, shafts, bolts, nuts, gearboxes,
sprockets, chains, cutter blades, keys, and keyways and developing a 3D model of each part and
also assembly of the part using CAD software (solid work), this machine is applicable in a sugar
factory.
Expected outcome
The machine is designed to have the ability to cut sugarcane stalks effectively, reduce human
labor, and avoid injuries to a worker. It has better performance than hand harvesting, as it can
harvest more sugarcane in less time. Moreover, these machines are made to be strong and
dependable, with robust materials that can resist the tough environment of sugarcane fields. As a
result, they need less maintenance and repair, which lowers downtime and improves overall
productivity.
The expected outcomes of the project are:
• All the parts of the machines such as pulleys and V-belts, shafts, bolts and nuts, bevel
gears, and blades for the cutter, keys, and keyways will be designed according to the
specifications.
• A 3D model of the machine will be created by using CAD software, such as solid work.
4
1.5 Significance
Small-scale sugarcane harvesting machines are significant in sugar factories because they help to
increase productivity. These machines are designed to harvest sugarcane quickly, reducing the
time and labor required for manual harvesting. The use of small-scale sugarcane harvester
machines Reduces the cost of production in sugar factories, by reducing the need for manual
labor, these machines can help to lower labor costs and improve profitability. Also, they can help
to improve the quality of the harvested sugarcane. These machines are designed to harvest the
cane without damaging it, ensuring that it remains intact and free from impurities.
In addition, small-scale sugarcane harvester machines are more advantageous than traditional
harvesting methods, which means that they can help to increase yields in sugar factories. This
increased yield can translate into higher profits for sugar producers. Also, they are easy to
operate and maintain. Unlike traditional harvesting methods, which require a great deal of skill
and experience, these machines can be operated by anyone with basic training.
It helps to improve worker safety in sugar factories. By reducing the need for manual labor, these
machines can help to reduce the risk of injury or accidents on the job and they can help to reduce
the amount of waste generated during the harvesting process. Generally, they can help to
improve the quality of the harvested cane by reducing the amount of dirt and debris that is
collected during harvesting and this can help to improve the overall quality of the sugar produced
by a factory.
1.6 Limitation
There are some drawbacks that will limit this project may restrict the desired out-come. Among
these limitations, the following are.
➢ It uses fuel so the cost of fuel is increased day to day.
➢ sugarcane harvesting machines are not able to collect the harvested crops of sugarcane,
which leads to an increase in the challenges for workers
5
CHAPTER TWO
2 LITERATURE REVIEW
2.1 The overview of sugarcane harvesting
Sugarcane is the world’s largest crop by production quantity. Sugar is produced in 120 countries.
Global production now exceeds 165 million tons a year. Approximately 80% is produced from
sugar cane, which is largely grown in tropical countries. The remaining 20% is produced from
sugar beet, which is grown mostly in the temperate zones of the northern hemisphere. Seventy
countries produce sugar from sugar cane, 40 from sugar beet, and 10 from both. The ten (10)
largest sugar-producing nations represent roughly 75% of world sugar production. Brazil alone
accounts for almost 25% of world production and was the largest producer of sugarcane in the
world[8].
Sugarcane has been grown in Ethiopia for centuries, with the first recorded cultivation dating
back to the 13th century. However, until recently, harvesting sugarcane was a labor-intensive
process that relied on manual labor. This changed with the introduction of sugarcane harvesters
in Ethiopia. The first sugarcane harvester was introduced in Ethiopia in the early 2000s by the
Ethiopian Sugar Corporation (ESC). The ESC is a state-owned company that oversees the
production and distribution of sugar in Ethiopia. The harvester was imported from Brazil and
was used to harvest sugarcane on ESC-owned plantations. The introduction of sugarcane
harvesters had a significant impact on the sugar industry in Ethiopia[9]. Today, there are several
different types of sugarcane harvester machines available in Ethiopia. Some are imported from
other countries, while others are locally manufactured. The level of these machines varies
depending on their quality and price range[10].
2.2 Method of harvesting and previous works
There are two main systems of sugarcane harvesting methods; Sugarcane harvesting manual and
Mechanical harvesting by a sugarcane harvester.
I. Manual harvesting systems
In the manual harvesting systems, the harvesting of sugarcane is done manually with the help of
human labor. Hand harvesting accounts for more than half of production, and is dominant in the
developing world. In hand harvesting, the field is first set on fire. The fire burns dry leaves, and
6
kills any lurking venomous snakes, without harming the stalks and roots. Labour then cut the
cane just above ground level using cane knives or machetes. Manually sugarcane harvesting is
more labor intensive and as compared to machine harvesting the cutting speed is very slow[7].
There are two basic systems are used to harvest the sugar cane manually:
Cut and stack green or burnt sugar cane

Cut and windrow green or burnt sugar cane for subsequent mechanical loading
Disadvantages of manual harvest are; Harvesting time will be more, Efficient work is not done,
the cost will be more, and ,Shortage of labor [11].
Figure 2-0-1;Infield sugar cane harvesting systems [12]
II. Mechanical harvesting systems
The mechanization of sugarcane harvesting is an essential input to modern agriculture, as it

enhances better productivity, besides reducing human drudgery and the cost of cultivation. The
cost of sugarcane harvesting by the mechanized process is almost one-third of a completely
manual process. Thus, sugarcane planter cutters are getting great responses from workers, due to
the reduction of drudgery involvement in unit operations, i.e., sett preparation, carrying of see a
cane, opening of furrows, dropping of setts, pesticide application, fertilizer placement, and
covering and pressing setts. Nowadays in many countries, mechanical sugarcane harvesters are
7
used for sugarcane harvesting. It is fully automated. It requires very less time for cutting
sugarcane around large areas. In mechanization, using a large-scale harvesting machine takes
about 6-7 hours to harvest one acre, averaging about 60-70 tons. Disadvantages of mechanized
harvesting are; The cost of the machine is high; the machine is meant for large scale farms and
requires skilled labour to operate[13].
Normally there are two sugarcane mechanical harvesting systems classified as follow:
❖ Whole-stalk sugarcane harvesting system (the system which delivers whole stalk of canes).
Large self-propelled whole stalk harvesters operated only within full mechanization systems.
Other tractor mounted machines or small single axle Walkman steering cane cutters are
fabricated for the conditions of developed countries and
❖ Cut-chop-harvesting or chopper harvesting system (the system which chop the cane into
billets while harvesting). This system is also called sugarcane combine harvesting system.
The chopper harvester (sugarcane combine) represents full mechanization system for
sugarcane harvesting. A transport trailers with especially basket design should move in the
field parallel to the machine to receive the current of cane billets delivered from the chopper
elevator[14].
2.2.1 Equipment of full mechanization sugarcane harvesting
Full mechanization of sugarcane harvesting and delivery may be applied for the entire sugarcane
production of Australia, USA and Japan. Countries such as Brazil, Cuba, South Africa, India,
China and many other countries apply full mechanization for harvesting large agricultural
sectors. The economy of owning and operating any sugarcane harvesting machine determines the
existing level of mechanization at certain conditions[15].
I) Self-propelled whole stalk harvester
The self-propelled whole-stalk sugarcane harvester is a machine for full mechanization of

sugarcane harvesting should perform the following functions in sequence; 6- Positioning and
handle the cane in respect to functional mechanisms,2- Cut the base of cane stalk,3- Cut the
green top of the cane stalk,4- Clean cane stalks from dry leaves (de-trashing),5- Place cane stalk
in a suitable manner for further operations and 6- Or convey cane harvested from several furrows
and place them together to form a windrow[16].
8
The necessary elements of a whole-stalk harvester are[17]:
➢ Dividers to gather the cane in the row being cut, and to separate it from cane in adjoining
rows.
➢ Base-cutters to sever the cane at ground level.
➢ A feeding device to take the cane from the base-cutters, and convey it through the machine.
➢ A cleaning device to remove and discard trash and tops.
➢ A bin to accumulate cane, and discharge it in neat piles, far enough from the cane face to
allow passage of the machine on its next pass, and onto ground which has been cleared of
trash.
Figure 2-0-2 Self-propelled whole stalk sugarcane harvester [17]

Disadvantages[18]:
➢ Whole-stalk harvesters are not always able to handle the crop. Lodged and recumbent
crops present extreme difficulties for this type of machine, as do yields in excess of 120
t/ha.
➢ Separate infield loading equipment is required.
➢ Mechanical loading of whole stalk could increase soil content in the cane sample.
➢ Some whole stick machines (soldier harvesters) have a high center of gravity, making
them unsuitable where slopes exceed10%. Most other whole stalk machines cannot
operate on slopes greater than 15-20%.
➢ Transport load densities are lower for whole stalk than for chopped cane.
9
II) Chopper harvester (sugarcane combine)
Chopper harvester is the most capable single machine that performs all the operations needed
for sugarcane harvesting in one pass. In the chopper harvester should be capable to perform the
following sequence of functions; Gather and feed the cane toward the functional mechanisms,
Cut the base of cane stalk, Cut the green top of the cane stalk, feed cane stalks inside the
machine, Chop cane stalks into billets, blow out green tops and dry leaves and elevate chopped
cane up to be loaded on a vehicle[19].
Figure 2-0-3Chopper harvester (sugarcane combine) [19]

Disadvantages[20]:
➢ The high capital outlay makes this system appropriate only for large scale growers and
contracting groups.
➢ Harvesting, transport and milling operations are linked, which means that communication
and transport scheduling is vital to obtain optimum harvester utilization.
➢ Receiving facilities at mills that usually handle whole stalks would have to be adapted.
➢ Cane losses are generally higher compared with whole stick harvesting systems.
➢ Chopped cane deteriorates more quickly than whole stalks and ideally should be crushed
within 12-14 hours after harvesting. This may increase transport costs.
➢ High levels of managerial/operator skill and technical support are required.
2.2.2 Equipment of semi mechanization sugarcane harvesting
Equipment of semi mechanization of sugarcane harvesters are all whole stalk harvesting
machinery. Sugarcane cutters may be tractor attached, ridden or Walkman steering machine.
10
Cutting the base of cane stalks is the primary function for any of the mechanical sugarcane
harvesters. A semi mechanization harvester may include one or more function such as topping
and/or cleaning in addition to stalk base cutting function[21].
I) McConnel sugar cane harvester of Barbados
The McConnel harvester was a new concept in sugar cane harvesting, it was tested in
commercial fields under a wide range of conditions, and it has recently been developed in
(BSPA) Barbados by the Sugar Producers Association and F. W. McConnel Ltd., England. The
stage (I) McConnel harvester is mounted on a standard 75 hp agricultural tractor. In particular,
the Stage (I) machine has been equipped with sharpened base cutter blades and mounted on a
reversed tractor. Stage (II) now cleans trash and, tops on the bottom "fan" only with significant
performance improvements. The cane is lifted to the conveyor from the gathering sweeps of a
powered roller, instead of a stationary ramp, allowing work in more wet conditions. The
"Loadstar" has been simplified by eliminating the telescopic extension [22].
II) SASABY sugar cane harvester of South Africa
SASABY was developed in South Africa for green cane harvesting from January 1978 to
December 1979. The SASABY whole stalk green cane harvester was designed, built, and tested.
A second SASABY was subsequently built to correct the shortcomings of the rear. Up to 200 kg
of cane is collected before it is dumped in bundles on the ground. The evolution of the Sasex
cutter for the whole stalk sugar cane. The original concept was a very simple machine known as
the "Cane Sny". From this was developed an economical cane cutter able to operate under a wide
the first. The SASABY (II) cut a single row of cane and fedd it into a bin. A crane with a grab
mounted on the harvester loaded the cane directly from the 5in into trailers traveling alongside
the harvester. This machine could harvest 30 t h-1 at which rate the extraneous matter content
was 8% and losses were less than 5%. The experience gained from SASABY I and II was used
to build a third prototype which is a smaller machine built onto a Ford 6600 tractor. It is a single-
row harvester that delivered cleaned cane into a bin at the rear. Up to 200 kg of cane is collected
before it is dumped in bundles on the ground [23].
11
III) Other tractor mounted sugarcane harvesters
Tractor attached sugar cane harvester cutters may be front mounted, midway mounted or rear
mounted machines[24]. The highlighted the most important demands have to be satisfied in
sugarcane cutter are; Able to cut unburned cane of up to 100 tons per hectare, Tolerant of rough-
and-ready field preparation, able to cut from furrows, ridges, tied-furrows or flat-planting, Able
to work in stony conditions, Tolerant of variable row spacing and of wide Raton stools and Able
to negotiate difficult headlands, in-field ditches. The South African made sugarcane harvester
VICRO equipped with full-hydraulic drive. It can continuously and automatically complete the
whole harvesting process of picking up fallen cane, topping, cutting, transmitting, truncating,
separating cane and top, loading with truck elevate. The purpose of the sugar Cane Harvester is
to be able to harvest and top burnt sugar cane as well as un-burnt sugar cane. The sugar cane
harvester is attached to any tractor by means of the two-point tractor linkage. The sugar cane
cutter was designed and built in South Africa. The cane cutting machines are easily disassembled
and shipped to any country in the world[25].
Figure 2-0-4 VICRO South African made sugarcane harvester[25]
IV) Ridden and walking man steering sugarcane cutters
Ridden type sugarcane harvesters have been fabricated in Japan and other Asian countries[26]. A
new low-cost, self-propelled, single-axle walking-type sugarcane harvester powered by 6-kW (8-
hp) gasoline engine. It was primarily designed for farmers of developing countries who cannot
afford to purchase expensive sugarcane harvesters used in developed countries. This machine
12
reduced labor requirements for cutting and windrowing sugarcane stems. In field tests, the
average field capacity of the machine was found to be 0.13 ha/h (0.32 acre/h) with average field
efficiency of 71%[27]. Figure show two types of the walking man hand steering sugarcane
harvester.
Figure 2-0-5 Walking type sugarcane harvesters in operation [27]
2.3 literature gap

As reviewed on the above relevant literatures, the following gaps are observed: The ease of use
of small-scale sugarcane harvesting machines is an area of concern. These devices often operate
carefully and with a lot of manual labor. This might make it challenging for workers to rapidly
and effectively harvest their crops. And also, the safety of these machines. If not used
appropriately, small-scale sugarcane harvesting equipment might be harmful. Workers must have
the necessary training to operate these machines safely.
In conclusion, after reviewing various journal papers, it was found that there are several gaps in
small-scale sugarcane harvesting machines that the existing machines were not economical and
the mechanism involved is complex. this project seeks to build a suitable sugarcane harvesting
machine with a simpler mechanism for cutting the sugarcane at a faster rate in order to save time
and effort in order to address these issues.
13
CHAPTER THREE
3 METHODOLOGY AND MATERIAL SELECTION
3.1 Methodology
This project started with an observation and problem identification, gathering information, and
discussion about the design development of a sugarcane harvesting machine. After gathering and
collecting all related information and obtaining new ideas and knowledge about the project
would continue with the design process. After visualization of the problem, we intensified to find
solutions to problems by performing the following progress.
Design procedure
Problem identification
Primary data Data collection Secondary data
Data analysis Make functional Structure
Force and Component dimension

Stress Analysis Detail Design Analysis
Material Selection Cost Analysis

.
Yes No
Assemble drawing and 3D

Modeling
Figure 3-0-1; flow chart of methodology

14
Problem identification
The problem is that the traditional method of harvesting sugarcane is labor-intensive and time-
consuming. The manual process involves cutting the sugarcane stalks with a machete or sickle,
which requires a lot of physical effort and can result in injuries to the workers. Moreover, it is
difficult to maintain uniformity in the cutting process, which affects the quality and quantity of
the harvested crop. Therefore, a small-scale sugarcane harvesting machine that can reduce labor
costs, increase productivity, and improve crop quality.
Data collection
i. Primary Data Collection
Site inspections to sugarcane farms to observe the existing harvesting techniques and identify the
challenges that workers encounter.
Figure 3-0-2 harvesting sugar cane on a plantation in Malawi, Africa Stock Photo [28]
ii. Secondary Data Collection

The secondary data collection involved reviewing academic literature on sugarcane harvesting
techniques and machinery development, as well as using data handbooks and design books for
the proper selection of machine elements. Other mechanical projects related to this project were
also consulted and studied.
15
Detail design
This step was to derive, analyze, and modify different designs for the sugarcane harvesting
machine. This step involved force analysis and load calculations of different components of the
machine, such as pulleys, belts, shafts, gears, blades, etc. The component size or dimension
analysis was also done to select the appropriate engine for the machine. Moreover, the force and
stress analysis for each component was performed to ensure the strength and durability of the
machine. The material selection for each part was also done based on the cost analysis and
availability.
3D modeling parts and Assemble drawing
The fourth step was to create a 3D model of the machine using CAD software (SolidWorks). The
3D model showed the details of each component and how they were assembled together. The
assembly drawing also showed the dimensions and specifications of each part.
3.2 Material selection
The selection of proper material, for sugarcane harvesting machine, is one of the most important
for the designer. The best material is one which serve the desired objective at minimum cost.
The following factor should be considering while selection of material:
➢ Availability of a proper material,

➢ Suitability of the material for which for the working conditions in the service.
➢ The cost of the materials.
The important properties, which determine the utility of the material are physical property,
chemical properties, and mechanical properties.
Physical properties of materials: The physical properties of materials include luster, color, size,
and shape, density, electrical and thermal conductivity, and melting point.
Mechanical property of materials: The mechanical properties of the metals are those which are
associated with the ability of the material to resist mechanical forces and loads. These
mechanical properties of metals including strength, stiffness, elasticity, plasticity, ductility,
malleability, toughness, resilience, creep and hardiness.
16
Gear material
The material used for the manufacturing of gears depends up on the strength and service
conditions like wear, noise etc. the gears may be manufactured from metallic or non-metallic
materials. The metallic gears with cut teeth are commercially obtainable in cast iron, steel and
bronze. The non-metallic materials like wood, rawhide, compressed paper and synthetic resins
like nylons are used for gears, especially for reducing noise. The cast iron is widely used for the
manufacturing of gears due to its good wearing properties, excellent machinability and ease of
producing complicated shapes, casting method. The cast iron gears with cut teeth may
employed, where smooth action is not important. The steel is used for high strength gears and
steel may be plain carbon steel or alloy steel. The steel gears are usually heat treated in ordered
to combine properly the toughness and tooth hardness.
Shaft material
The material used for shafts should have the following properties:
➢ It should have high strength.

➢ It should have good machinability.
➢ It should have low notch sensitivity factor.
➢ It should have good heat treatment properties.
➢ It should have high wear resistant properties.
The material used for ordinary shafts is carbon steel of grades 40 C 8, 45 C 8, 50 C 4
Belt material
Belt material is different kind from one of them is leather type belt is good for any application
area and use, so in this case leather type belt is selected.
Pulley material
Most of time pulley material are cast iron and cast steel is also another type of pulley. According
to the principle of design cast steel is selected. This material has low cost and have high life time.
17
Material selection of key
Because key is loaded in shear, ductile material is used. Soft low carbon steel is most common
choose unless a corrosive environmental required a brass or stainless-steel key used. Square or
rectangular key often made from cold roller bar stock and merely cut to length. But for this
design cast iron is selected, because of its good machinability.
Cutter
The blade of a knife can be made from a variety of materials, the most common being carbon
steel, stainless steel, tool steel and alloy steel. Other less-common materials used in knife blades
include: cobalt and titanium alloys, ceramics, obsidian, and plastic.
Carbon steel is a popular choice for rough use knives. Carbon steel tends to be much tougher and
much more durable, and easier to sharpen than stainless steel. They lack the chromium content of
stainless steel, making them susceptible to corrosion.
Carbon steels have less carbon than typical stainless steels do, but it is the main alloy element.
They are more homogeneous than stainless and other high alloy steels, having carbide only in
very small inclusions in the iron. The bulk material is harder than stainless, allowing them to
hold a sharper and more acute edge without bending over in contact with hard materials. But
they dull by abrasion quicker because they lack hard inclusions to take the friction. This also
makes them quicker to sharpen. Carbon steel is well known to take a sharper edge than stainless.
18
3.3 Working principle
The working principle of the machine is as follows: The fuel from the tank is supplied to the
engine and the power is generated to the shaft inside the engine. The driver pulley or belt and the
gearbox are attached to the engine shaft. The engine shaft rotates the driven pulley through the
belt drive mechanism. The driven pulley that is connected to the longer shaft will transmit the
power to both sides of the bevel gears through the shaft. The longer shafts will be mounted
between the two plumber blocks or bearing housings which provide support to the shaft and
prevent it from moving or bending. The rotating bevel gears are in turn connected to the cutters
through vertical shafts which rotate the cutters. The cutter blades rotate and cut the sugarcane
stalks at the base and top. The gearbox reduces the engine shaft speed and transfers it by chain to
the sprocket that is mounted to shafts that rotate the wheels. In this way, the small-scale
sugarcane harvesting machine works. The operations involved are simple and easy to operate.
The machine is moved by hand through the field to perform the cutting action. This means that
someone has to push or pull the machine along the rows of sugarcane and adjust its direction and
position to make sure it cuts all the stalks properly.
Figure 3-0-3; 3D model of small-scale sugarcane harvesting machine
19
CHAPTER FOUR
4. DESIGN ANALYSIS
4.1 Design consideration
Row spacing
The main consideration in the design of a harvesting system is the amount of crop that is to be
harvested and conveyed through the conveying system per meter run of the machine. This
decides the capacity of the machine with respect to the width of the operation. In a crop situation
where row cultivation is practiced, the width of the machine is directly linked with the sugarcane
row spacing. Hence, the present investigation is done on the existing pattern of cultivation with
respect to row spacing. The optimum spacing for planting of sugarcane is 0.75 to 1.0m between
rows[29]. Where growth of the plant is restricted due to climatic parameters, a row spacing of
0.75m is adopted. The fields at different locations are studied for finding out the existing row
spacing of the crop, to decide the optimum spacing of the crop divider and the effective width of
the base cutter. In our country the climate is safe so the spacing between is 750mm or 0.75m[30].
Length of the cane
The length of the mill able cane varies between 1200mm and 2700mm. The maximum and
minimum diameters are 40 and 20mm respectively. But most of the sugarcane length is 2000mm.
Engine selection (standard)
An engine is a device that transforms energy into movement or mechanical work. The engines
that burn fuel inside the engine cylinder are called internal combustion engines (I. C. engines for
short). They can use either petrol or diesel as their fuel. The I.C. engines can have two or four
piston strokes to complete one operating cycle. For this machine, two stroke petrol engines are
more suitable according to the objective. Petrol engines have some advantages over diesel
engines, such as being quieter, smoother, lighter and cheaper. They also have a higher power to
weight ratio, which means they can speed up faster and they produce less harmful substances like
particulate matter and nitrogen oxides (NOx) than diesel engines, making them more eco-
friendly. Compared to the previous sugar cane harvesting machine and based on efficiency, size,
cost and maintenance, a 4.6 kW single cylinder 2 stroke, air cooled, petrol engine is chosen and
20
the engine shaft speed is 5500rpm (575.67 rad/s). The power of 4.6 kilowatts is equivalent to
6.17 horsepower [31].
P = 4.6 kW x 1.36 hp = 6.25 hp.
Calculating the engine torque
P
T = (4.1)
ω
Where P: engine power, expressed in n W
T: engine torque, expressed in Nm
ω: angular velocity, expressed in rad/s
4600w
T = = 8 Nm
575.67 rad/s
4.2 Design of pulley and V belt

The pulleys are used to transmit power from one shaft to another by means of flat belts, V-belts
or ropes. Since the velocity ratio is the inverse ratio of the diameters of driving and driven
pulleys, therefore the pulley diameters should be carefully selected in order to have a desired
velocity ratio. The pulleys must be in perfect alignment in order to allow the belt to travel in a
line normal to the pulley faces. The pulleys may be made of cast iron, cast steel or pressed steel,
wood and paper. The cast materials should have good friction and wear characteristics. The
pulleys made of pressed steel are lighter than cast pulleys, but in many cases, they have lower
friction and may produce excessive wear. Select V belt drive for this small center distance
application.
Advantages and Disadvantages of V-belt Drive over Flat Belt Drive
Following are the advantages and disadvantages of the V-belt drive over flat belt drive:
Advantages
➢ The V-belt drive gives compactness due to the small distance between centers of pulleys.
➢ The drive is positive, because the slip between the belt and the pulley groove is
negligible.
21
➢ Since the V-belts are made endless and there is no joint trouble, therefore the drive is
smooth. 4. It provides longer life, 3 to 5 years.
➢ It can be easily installed and removed.
➢ The operation of the belt and pulley is quiet.
➢ The belts have the ability to cushion the shock when machines are started.
➢ The high velocity ratio (maximum 10) may be obtained.
➢ The wedging action of the belt in the groove gives high value of limiting *ratio of
tensions. Therefore, the power transmitted by V-belts is more than flat belts for the same
coefficient of friction, arc of contact and allowable tension in the belts.
➢ The V-belt may be operated in either direction, with tight side of the belt at the top or
bottom. The center line may be horizontal, vertical or inclined.
Disadvantages
➢ The V-belt drive cannot be used with large center distances, because of larger weight per
unit length.
➢ The V-belts are not as durable as flat belts.
➢ The construction of pulleys for V-belts is more complicated than pulleys of flat belts.
➢ Since the V-belts are subjected to certain amount of creep, therefore these are not suitable
for constant speed applications such as synchronous machines and timing devices.
➢ The belt life is greatly influenced with temperature changes, improper belt tension and
mismatching of belt lengths.
The centrifugal tension prevents the use of V-belts at speeds below 5 and above 50 m / s.
Rated power of Engine
𝑃𝑅 = 6.25 HP = 4.6 KW
Speed of Engine, 𝑁1 = 5500 𝑟𝑝𝑚
Design Power PD = PR *Sf (4.2)
Service factor Sf = 1.45
PD = 4.6KW ∗ 1.45 = 6.67 KW
22
Now select designation from design power, Designation is ‘’B’’ From dimensions of
standard V belts according to IS:2494-1974
D1 = Diameter of smaller pulley
D1 = 125 mm
W = 17 mm, t = 11 mm, centrifugal tension factor Kc = 4.34
πDN π∗0.125∗5500rpm
Pitch line velocity Vp = = (4.3)
60 60
Vp = 36 m⁄s
Assume velocity ratio V. R = 2: 1
N1
= V. R (4.4)
N2
N1
N2 =
2
5500rpm
N2 = = 2750rpm
2
To find larger diameter of pulley
N1 D2
= (4.5)
N2 D1
From this equation we can find larger diameter D2
N1∗D1 5500rpm∗125mm
D2 = = = 250mm
N2 2750rpm
Where r1 and r2 = radii of the larger and smaller pulleys
x1 =Distance between the centers of two pulleys
L = Total length of the belt
23
250mm
r2 = = 125mm
2
125𝑚𝑚
r1 = = 62.5mm
2
Let center distance x= 375mm

r2−r1
α = sin−1 ( (4.6)
x
125mm − 62.5mm
α = sin−1 ( ) = sin−1 (0.166)
375
α = 100
Angle of contact pulley

D2−D1
θ± Or θ = 1800 − 2α (4.7)
X
θ = 1800 − 2 ∗ 100 = 1600 =2.8 rad

Belt pitch length is calculated as:
(r2 −r1 )2
L = 2X + π(r2 + r1 ) + (4.8)
x
(125mm − 62.5mm)2
L = 2 × 375mm + 3.14(125mm + 62.5mm) +
375mm
L= 1349.2mm, but standard length is 1339mm
Face width can be calculated
Minimum pitch diameter of pulley (d) = 125mm
From table: Top width (w) = 17mm
Thickness (t) = 11mm
B = w – 2t ∗ tan( β), (4.9)
Groove angle β =32 °, 34 °, 38°
B = 17 − 2 × 11tan32°
24
Face width B = 3.25mm
1
Area (A) = (w + B)𝑡 (4.10)
2
1
A= (17mm + 3.25mm)11 mm
2
A = 111.4𝑚𝑚2
Mass of the belt is calculated as
M = A × L × Þ (4.11)
Where M = mass of the belt
A = area of the belt
L = length of the belt

𝑘𝑔
M = 111.4𝑚𝑚2 × 139mm × 1000
𝑚3
M = 0.149 Kg
Various tensions acting on the belt[32].

PD
= T1 − T2 (4.12)
Vp
Where T1= tension of tight side
T2 = tension of slack side
PD = designed power
VP = pitch line velocity
6.67KW
T1 − T2 = 𝑚 = 185.3N
36
𝑠
25
T1 − T2 = 185.3N (4.13)
T1
2.3 log ( ) = μ. θ cosec β (4.14)
T2
Where coefficient of friction (μ) = 0.3
θ = 2.8rad
2β = 32°
T1
Then 2.3 log ( ) = 0.3 ∗ 2.8rad ∗ cosec(16°) = 2.839
T2
T1 2.839
log ( ) = = 1.2317
T2 2.3
T1
log ( ) = 1.2317 ……. (Taking antilog of 1.2317)
T2
T1
= 13.2N (4.15)
T2
From equation (4.13) and 4.15)
We get T1 = 200.5N
T2 = 15.2N
The maximum power the belt can transmit is:
P max = (T1 − T2) ∗ Vp
𝑚
P max = (185. 3N ) ∗ 36
𝑠
P max = 6.67KW
𝐷𝑒𝑠𝑖𝑔𝑛𝑒𝑑 𝑝𝑜𝑤𝑒𝑟 4.67𝐾𝑊

Number of belts required (n) = = = 0.7 say 1
𝑃𝑜𝑤𝑒𝑟 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑 𝑝𝑒𝑟 𝑏𝑒𝑙𝑡 6.67𝐾𝑊
26
Therefore, the number of belts to transmit the maximum output power is one belt.
Initial Tension in the Belt
When a belt is wound round the two pulleys (i.e., driver and follower), its two ends are joined
together, so that the belt may continuously move over the pulleys, since the motion of the belt
(from the driver) and the follower (from the belt) is governed by a firm grip due to friction
between the belt and the pulleys. In order to increase this grip, the belt is tightened up. At this
stage, even when the pulleys are stationary; the belt is subjected to some tension, called initial
tension.
When the driver starts rotating, it pulls the belt from one side (increasing tension in the belt on
this side) and delivers to the other side (decreasing tension in the belt on that side). The increased
tension in one side of the belt is called tension in tight side and the decreased tension in the other
side of the belt is called tension in the slack side.
Tc = Initial Tension in the Belt
2 2 2
√𝑇1 + √𝑇2 = 2 √Tc (4.16)
2 2 2
√200.5 𝑁 + √15.2N = 2 √Tc
Tc=81.6N
Pulley
Pulleys are generally made of cast iron because of low cost, good casting characteristics, high
compression strength, and high wear resistance and excellence machinability. The pulleys less
than 200mm diameter are made with solid disc instead of arms. The thickness of the solid is
taken equal to the thickness of the rim measured at the center of pulley face Number of grooves
on the pulleys =1, for one belt 6.67kw power rating.
Material: alloy steel or cast iron. From dimensions of standard V-grooved pulleys according to
IS:2492-1974
27
For smaller pulley D1=125mm
LP= 14 mm, a = 4.2 mm, h = 10.8 mm, e = 19 mm, f = 12.5 mm, number of belt(n)= 1
Face width, 𝐵 = (𝑛 − 1) ∗ 𝑒 + 2𝑓
𝐵 = (1 − 1) ∗ 19𝑚𝑚 + 2 ∗ 12.5𝑚𝑚 = 25𝑚𝑚
Larger pulley, D2= 250 mm
Figure 4-0-1 Pulley connected with shaft
4.3 Design of shaft

Introduction
A shaft is a rotating machine element which is used to transmit power from one place to another.
The power is delivered to the shaft by some tangential force and the resultant torque (or twisting
moment) set up within the shaft permits the power to be transferred to various machines linked
up to the shaft. In order to transfer the power from one shaft to another, the various members
such as pulleys, gears etc., are mounted on it. These members along with the forces exerted upon
them causes the shaft to bending. In other words, we may say that a shaft is used for the
28
transmission of torque and bending moment. The various members are mounted on the shaft by
means of keys or splines.
Notes: 1. the shafts are usually cylindrical, but may be square or cross-shaped in section. They
are solid in cross-section but sometimes hollow shafts are also used.
Material Used for Shafts
The material used for shafts should have the following properties:
➢ It should have good machinability.

➢ It should have low notch sensitivity factor.
➢ It should have good heat treatment properties.
➢ It should have high strength
➢ It should have high wear resistant properties
The material used for ordinary shafts is carbon steel of grades 40 C 8, 45 C 8, 50 C 4 and 50
C12.When a shaft of high strength is required, then alloy steel such as nickel, nickel-chromium
or Chrome vanadium steel is used.
Types of Shafts
The following two types of shafts are important from the subject point of view:
1. Transmission shafts. These shafts transmit power between the source and the machines
absorbing power. The counter shafts, line shafts, overhead shafts and all factory shafts are
transmission shafts. Since these shafts carry machine parts such as pulleys, gears etc., therefore
they are subjected to bending in addition to twisting.
2. Machine shafts. These shafts form an integral part of the machine itself. The crank shaft is an
example of machine shaft.
Stress in shaft
The following stresses are induced in the shafts:
➢ Shear stresses due to the transmission of torque (i.e., due to torsional load).
➢ Bending stresses (tensile or compressive) due to the forces acting upon machine elements
like gears, pulleys etc. as well as due to the weight of the shaft itself.
29
➢ Stresses due to combined torsional and bending loads.
Material
Carbon steel of grades 40 C 8,
Ultimate tensile strength = 560 - 670 MPa
Yield strength = 320 MPa
To calculate mass of the pulley, neglect the internal diameter. For the pulley it will be
compensated by the mass of the hub.
Face width of the pulley B = (2 − 1) × 19 + 2 × 12.5 = 25mm
Diameter of the pulley D is 250mm = 0.25m
𝑘𝑔
Density of the pulley material (cast iron) ρ = 7250
𝑚3
𝜋𝑑 2
Volume of pulley (v) = ∗𝐵 (4.16)
4
𝜋0.252
(V) = ∗ 0.025𝑚
4
(V) = 1.226 × 10−3 𝑚3
Mass of the pulley (M) = Volume of pulley (v) × density (ρ) (4.17)
𝑘𝑔
𝑀 = 1.226 × 10−3 𝑚3 × 7250
𝑚3
𝑀 = 8.89𝑘𝑔
Weight of the pulley (WP) = Mass of the pulley (M) ×gravity (g) (4.18)
𝑚
Wp = 8.89 𝑘𝑔 × 9.81
𝑠2
Wp = 87𝑁
30
Design of torque
60𝑃𝐷
𝑇D = (4.19)
2𝜋𝑁
Where PD = designed power
N = speed of engine shaft
Material
Carbon steel of grades 40c8
Ultimate tensile strength = 560MPa to 670MPa
Yield strength =320Mpa
Design of horizontal shaft
60∗6.67kw
𝑇D =
2𝜋∗5500𝑟𝑝𝑚
TD = 11.57 N-m torque transmitted by the shaft
Force acting on the horizontal shaft
Reaction forces
Weight of gear Weight of pulley Weight of gear
A C E
B D
Figure 4-0-2 Reaction force of horizontal shaft
31
Total vertical load acting downward on the shaft at point C = 𝑇1 + 𝑇2 + 𝑊𝑝
Where T1 = tension of tight side
T2 = tension of slack tide
Wp = Weight of pulley
Total vertical load acting downward on the shaft at point Vc = 200.5𝑁 + 12.5𝑁 + 87𝑁
Vc = 300𝑁
Assuming the torque on the gear E and A is the same as that of shaft, then tangential force (F)
acting
Vertically downward on the gear A and E

𝑇𝑜𝑟𝑞𝑢𝑒
Tangential force =
𝑟𝑎𝑑𝑖𝑢𝑠
T
Ft = (4.20)
r
11.58𝑁𝑚
𝐹t = = 257.3N
90∗0.5
Weight of gear is 85.53N
Tangential force acting on gear A = 257.3 + 85.53 = 342.83N
Tangential force acting on gear E = 257.3 + 85.53 = 342.83N
Length of shaft is 750 mm because sugarcane raw spacing is between 750mm-1000mm but in
our country the condition is safe so 750 mm is length of shaft.
32
Figure 4-0-3 Reaction force of vertical shaft

∑Fy = 0
𝑅𝐵 + 𝑅𝐷 = 342.83𝑁 + 256𝑁 + 342.83𝑁
𝑅𝐵 + 𝑅𝐷 = 941.66 N (4.21)
Bending moment at D
𝑅𝐶 × 0.187.5 + 𝑅𝐴 × 0.5625 – 𝑅𝐵 × 0.375 – 𝑅𝐸 × 0.1875 = 0
256 × 0.1875 + 342.83 × 0.5625 –𝑅𝐵 × 0.375 – 342.83 × 0.1875 = 0
RB = 470.83N and
RD = 470.83N
Bending moment at D
𝑀𝐷 = 342.83N × 0.1875m = 64.28Nm = 64.28 ∗ 103 𝑁𝑚𝑚
Bending moment at B is the same as at D
We see that bending moment at B and D is same.
33
Figure 4-0-4 Bending moment diagram
Equivalent twisting moment 𝑇𝑒 = √(𝑘 ∗ 𝑀)2 + (𝐾 ∗ 𝑇)2 (4.22)
Where km and kt recommended value for stationary shaft and rotating shaft for medium shock
loads.
𝑇𝑒 = √(1.5 ∗ 64.28𝑁𝑚)2 + (1.5 ∗ 11.58𝑁𝑚)2
𝑇𝑒 = 98Nm
We also know that equivalent twisting moment (𝑇𝑒 )
τ∗π∗𝑑 3
𝑇𝑒 = (4.23)
16
Where τ = shear strength
d = diameter of shaft
Ultimate tensile strength of shaft material is σu = 56MPa
Ultimate shear strength is τ = 0.67 × 560Mpa = 375.2 MPa

τ
Take factor of safety to be 10 for cast iron τ =
10
375.2 MPa
𝜏=
10
τ = 37.52MPa
16∗𝑇𝑒
From the equation 𝑑3 =
𝜋∗τ
16 ∗ 98Nm
𝑑3 =
𝜋 ∗ 37.52MPa ∗ 106 Nmm
34
d = 26.55mm
Then d = 26.55mm take standard 30mm
Design of vertical shaft

Vertical rod or vertical shaft is used to rotate upper and lower cutters which receive power from
horizontal shaft by the help of bevel gear.
60P
𝑇 =
2𝜋𝑁
Where T = cutting torque
P = power 5.75kw for steady and continues work

60 ∗ 5.75kw
T =
2 ∗ π ∗ 2750rpm
T = 19.97N − m
τ∗π∗d3
And from the equation Te =
16
From this equation we can find diameter of shaft
16 ∗ Te
d3 =
π∗τ
16 ∗ 19.97N − m
d3 =
π ∗ 37.52 MPa
D = 14mm
Increase diameter by 50% to sustaining various loads and considering for the key way.
d = 1.5 × 14 mm = 21mm take standard (d) = 25mm
4.4 Design of cutter (bottom cutter)
A cutter in a sugar cane harvesting machine is a rotating blade or cutting mechanism that cuts the
sugar cane stalks at the base, separating them from the roots and leaves. The cutter is an essential
component of the machine as it enables efficient and rapid harvesting of sugar cane crops.
35
Material
The standard material selection for cutter blades in sugar cane harvesting machines is typically
high-carbon steel or alloy steel. These materials are chosen for their durability, strength, and
resistance to wear and corrosion. The blades are usually heat-treated to increase their hardness
and toughness, which helps them withstand the harsh conditions of cutting through tough sugar
cane stalks. Diameter of cutter we select 250mm with 100teeth it is available in the market
easily.
T = F × r (4.24)
Radius of the cutter is half of the diameter
D
T=F∗
2
But torque is split in to two vertical rods
19.97Nm
𝑇 =
2
T = 9.985Nm
2 ∗ 𝑇 2 ∗ 9.985Nm
𝐹= =
𝐷 0.25𝑚
F = 80N
80N is the cutting force by the lower cutter.

4.5 Design of upper cutter
T = F ∗ r
Diameter of blade is 500mm.
9.985Nm
F=
0.25m
𝐹= 39.9 N
39.9N is the cutting force by the upper cutter
36
4.6 Design of keys and keyways
A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley to connect
these together in order to prevent relative motion between them. It is always inserted parallel to
the axis of the shaft. Keys are used as temporary fastenings and are subjected to consider-able
crushing and shearing stresses. A keyway is a slot or recess in a shaft and hub of the pulley to
accommodate a key.
Material for the key
Steel SA-268
Nominal composition 12Cr-1Al
Yield strength σ𝑦 = 207MPa
Specified minimum tensile strength σ𝑡 = 414 MPa
Types of Keys
The following types of keys are important from the subject point of view:
Sunk keys, Saddle keys, Tangent keys, round keys, and Splines.
Sunk Keys
The sunk keys are provided half in the keyway of the shaft and half in the keyway of
the hub or Boss of the pulley. The sunk keys are of the following types:
Rectangular sunk key. The usual proportions of this key are:
𝑑 2𝑤 𝑑
Width of key, w = ; and thickness of key, t = =
4 3 6
Where d = Diameter of the shaft or diameter of the hole in the hub.

The key has taper 1 in 100 on the top side only.
37
Square sunk key.
The only difference between a rectangular sunk key and a square sunk key is that its width and
𝑑
thickness are equal, i.e., w = t =
4
Parallel sunk key.
The parallel sunk keys may be of rectangular or square section uniform in width and thickness
throughout. It may be noted that a parallel key is a taper less and is used where the pulley, gear
or other mating piece is required to slide along the shaft.
Gib-head key.
It is a rectangular sunk key with a head at one end known as gib head. It is usually provided to
facilitate the removal of key.
Feather key.
A key attached to one member of a pair and which permits relative axial movement is known as
feather key. It is a special type of parallel key which transmits a turning moment and also permits
axial movement. It is fastened either to the shaft or hub, the key being a sliding fit in the key way
of the moving piece.
Since sunk key is half in the pulley and half in the shaft select sunk Key Square shaped. We
select square shape for simplicity of design and manufacturing.
𝑑 30
𝑊 = 𝑡 = =
4 4
𝑊 = 7.5𝑚𝑚
The length of key is obtained by considering the key in shearing and crushing.
Let l = minimum Length of key.
Consider shearing of the key. We know that shearing strength (or torque transmitted) of the key,
38
𝑑
𝑇 =𝑙∗𝑤∗τ∗ (4.25)
2
𝜏 = 0.67 ∗ σ𝑡
τ = 0.67 ∗ 414 MPa = 277.38MPa
Take factor of safety f.s = 8 (live load)
𝜏
𝜏𝑎 = (4.26)
𝑓.𝑠
277.38MPa
𝜏𝑎 = = 34.67 MPa
8
2𝑇 2∗98∗103 𝑁−𝑚𝑚
From equation 𝑙 = =
𝑊∗τ∗d 7.5𝑚𝑚∗34.67 MPa∗30mm
𝑙 = 25.125mm
Width of the pulley with the hub is 70mm
Take l = 70mm
4.7 Bearing Selection

Introduction
A bearing is a machine element which supports another moving machine element (known as
journal). It permits a relative motion between the contact surfaces of the members, while
carrying the load. A little consideration will show that due to the relative motion between the
contact surfaces, a certain amount of power is wasted in overcoming frictional resistance and if
the rubbing surfaces are in direct contact, there will be rapid wear. In order to reduce frictional
resistance and wear and in some cases to carry away the heat generated; a layer of fluid (known
as lubricant) may be provided. The lubricant used to separate the journal and Bearing is usually a
mineral oil refined from petroleum, but vegetable oils, silicon oils, etc., may be used.
39
Classification of Bearings
Though the bearings may be classified in many ways, yet the following are important from the
subject point of view: Depending upon the direction of load to be supported. The bearings under
this group are classified as: (a) Radial bearings, and (b) Thrust bearings.
Depending upon the nature of contact. The bearings under this group are classified as:
(a) Sliding contact bearings, and
(b) Rolling contact bearings.
Advantages and Disadvantages of Rolling Contact Bearings over Sliding Contact Bearings
Advantages
➢ Low starting and running friction except at very high speeds.

➢ Ability to withstand momentary shock loads.
➢ Accuracy of shaft alignment.
➢ Low cost of maintenance, as no lubrication is required while in service.
➢ Small overall dimensions.
➢ Reliability of service.
➢ Easy to mount and erect.
➢ Cleanliness.
Disadvantages
➢ Noisier at very high speeds.

➢ Low resistance to shock loading.
➢ More initial cost.
➢ Design of bearing housing complicated.
Types of Rolling Contact Bearings
Following are the two types of rolling contact bearings:

1. Ball bearings; and
2. Roller bearings.
The ball and roller bearings consist of an inner race which is mounted on the shaft or journal and
an outer race which is carried by the housing or casing. In between the inner and outer race, there
40
are balls or rollers. A number of balls or rollers are used and these are held at proper distances by
retainers so that they do not touch each other. The retainers are thin strips and are usually in two
parts which are assembled after the balls have been properly spaced. The ball bearings are used
for light loads and the roller bearings are used for heavier loads.
The rolling contact bearings, depending upon the load to be carried, are classified as
➢ Radial bearings
➢ Thrust bearings.
Standard Dimensions and Designations of Ball Bearings
The dimensions that have been standardized on an international basis are shown in figure. These
dimensions are a function of the bearing bore and the series of bearing. The standard dimensions
are given in millimeters. There is no standard for the size and number of steel balls. The bearings
are designated by a number. In general, the number consists of at least three digits. Additional
digits or letters are used to indicate special features e.g., deep groove, filling notch etc. The last
three digits give the series and the bore of the bearing. The last two digits from 04 onwards,
when multiplied by 5, give the bore diameter in millimeters. The third from the last digit
designates the series of the bearing.
Figure 4-0-5; standard designations of ball bearings[33]

The most common ball bearings are available in four series as follows:
1. Extra light (100), 2. Light (200),
3. Medium (300), 4. Heavy (400)
The extra light and light series are used where the loads are moderate and shaft sizes are
comparatively large and also where available space is limited. The medium series has a capacity
30 to 40 per cent over the light series. The heavy series has 20 to 30 per cent capacity over the
41
medium series. This series is not used extensively in industrial applications. Bore of the bearing
should be equal to diameter of our shaft 𝑑𝑠 = 30mm so,
➢ Bearing number 206, 306 or 406

➢ Bore = 5 x 6 = 30mm
➢ Outside diameter = 62, 72 or 90mm based on the load capacity
➢ Width = 16, 19, or 23mm
Basic Static Load Rating of Rolling Contact Bearings
The load carried by a non-rotating bearing is called a static load. The basic static load rating is
defined as the static radial load (in case of radial ball or roller bearings) which corresponds to a
total permanent deformation of the ball (or roller) and race, at the most heavily stressed contact,
equal to 0.0001 times the ball (or roller) diameter.
Here the static loads are: -
Vertically (𝐿𝑣 ) – weight of pulley, weight of shaft, weight of gear in both sides of shaft
Weight of pulley(𝑊𝑝 ) = 87N
Weight of gear (𝑊𝐺 )= 85.53N but
Weight of gear is both sides of shaft then 2 ∗ 85. 53𝑁 = 171.06𝑁
π∗ds2
Volume of the shaft (V) = ∗L (4.27)
4
π ∗ 0.03m2 −4
V= ∗ 0.75m = 5.3 x 10 m3
4
Mass (m) = volume(𝑉) x density(Þ)
−4 𝑘𝑔
m = 5.3 x 10 m3 x 7250
𝑚3
m = 3.842kg
Weight of shaft ( Wsh ) = mass(m) * gravity(g)
m
(𝑊𝑠ℎ ) = 3.842 kg x 9.81 = 37.68 N
s2
42
𝐿v = WG + WSh + Wp (4.28)
Lv = 87N + 171.06N + 37.68N = 295.74N
Horizontally (𝐿𝐻 ) – the initial tension of the belt (TC ) = 81.6N
LH = 81.6N
Radial load (W) =√𝐿𝐻 2 + 𝐿𝑣 2 (4.29)
W =√(81.6N)2 + (295.74N)2 = 306.78N
This load is supported by the two bearings, so it should be divided by 2.
306.78N
𝑊 = = 153.89N
2
Static Equivalent Load for Rolling Contact Bearings

The static equivalent load may be defined as the static radial load (in case of radial ball or roller
bearings) or axial load (in case of thrust ball or roller bearings) which, if applied, would cause
the same total permanent deformation at the most heavily stressed ball (or roller) and race
contact as that which occurs under the actual conditions of loading.
Life of a Bearing
The life of an individual ball (or roller) bearing may be defined as the number of revolutions (or
hours at some given constant speed) which the bearing runs before the first evidence of fatigue
develops in the material of one of the rings or any of the rolling elements. Select the life of
bearing LH = 8000 hours (the second one from table 15) 8 hours per day for about three and half
years. And life of the bearing in revolutions,
𝐿 = 60 𝑁 × 𝐿𝐻 (4.30)
𝐿 = 60 × 2750𝑟𝑝𝑚 × 8 000ℎ𝑟
L= 132×107 rev
Basic dynamic load rating, the value of ‘k’ is 3 for ball bearing
43
1
𝐿
𝐶 = 𝑊𝑥( 6)
𝐾 (4.31)
10
132 ∗ 107 𝑟𝑒𝑣 1

𝐶 = 130.89𝑁 𝑥 ( )3
106
C = 1.4358KN
Figure 4-0-6 bearing connected with shaft
4.8 Design of bolt and nut

According to our design there are two bolts on each bearing. So, the bearing load is divided or
302.5N
supported by two. Meaning each bolt support a load of = 151.25N
2
From design of shaft

Summation of vertical loads ∑ 𝑅𝑣 = 200.5N + 152N
∑ 𝑅𝑣 352.5N
Summation of horizontal loads ∑ 𝑅𝐻 = 87𝑁 + 86𝑁 + 86𝑁
∑ 𝑅𝐻 = 259N
44
R =√R v 2 + R H 2 (4.32)
R= √(352.5N)2 + (259N)2 = 437.42 N
Material for the bolt and nut

Carbon steel of grades 40 C 8 is selected for bolts and nuts because it has a high tensile strength,
good ductility, and excellent toughness. It is also relatively inexpensive compared to other
materials. The carbon content in this grade of steel provides good hardness and wear resistance,
making it suitable for use in applications where the bolt or nut will be subjected to high stress or
wear
➢ Carbon steel of grades 40 C 8
➢ Yield strength 𝜎𝑦 = 320 𝑀𝑃𝑎
➢ Ultimate tensile strength is 𝜎𝑢 = 570 MPa
The ultimate shear strength is τ𝑢 = 0.67 ∗ 𝜎𝑢
𝜏𝑈 = 0.67 ∗ 570 𝑀𝑃𝑎
𝜏𝑈 = 382MPa
Stresses due to External Forces
The following stresses are induced in a bolt when it is subjected to an external load.
1. Tensile stress. The bolts, studs and screws usually carry a load in the direction of the bolt axis
which induces a tensile stress in the bolt.
Let dc = Root or core diameter of the thread, and
𝜎𝑡 = Permissible tensile stress for the bolt material.
Take factor of safety f.s = 10
𝜎𝑦 320𝑀𝑝𝑎
𝜎𝑡 = = = 32 MPa
𝑓. 𝑠 10
We know that external load applied,
𝜋
𝑝 = ∗ 𝑑𝑐 2 ∗ 𝜎𝑡 (4.32)
4
4𝑃 4 ∗ 151.25N
𝑑𝑐 = √ =√
𝜋𝜎𝑡 𝜋 ∗ 32 MPa
45
dc= 6.4mm
From design dimensions of screw threads, bolts and nut according to IS:4218 (part III) 1976
(reaffirmed1996) select M12 ×1.25
Major or nominal diameter Nut and Bolt (d = D) = 12.0
Effective or pitch diameter Nut and Bolt 𝑑𝑝 = 11.84
Minor or core diameter of bolt 𝑑𝑐 = 10.46
Minor or core diameter of nut 𝑑𝑐 = 10.647
Depth of thread (bolt) 𝑑𝑡 = 0.767
Stress area = 92𝑚2
4.9 Design of bevel gear

Introduction
The bevel gears are used for transmitting power at a constant velocity ratio between two shafts
whose axes intersect at a certain angle. The pitch surfaces for the bevel gear are frustums of
cones. The bevel gear is used to change the axis of rotational motion. By using gears of differing
numbers of teeth, the speed of rotation can also be changed
Classification of Bevel Gears
The bevel gears may be classified into the following types, depending upon the angles between
the shafts and the pitch surfaces.
1. Mitre gears. When equal bevel gears (having equal teeth and equal pitch angles) connect two
Shafts whose axes intersect at right angle, then they are known as Mitre gears.
2. Angular bevel gears. When the bevel gears connect two shafts whose axes intersect at an angle
other than a right angle, then they are known as angular bevel gears.
3. Crown bevel gears. When the bevel gears connect two shafts whose axes intersect at an angle
greater than a right angle and one of the bevel gears has a pitch angle of 90º, then it is known as a
crown gear. The crown gear corresponds to a rack in spur gearing.
46
4. Internal bevel gears. When the teeth on the bevel gear are cut on the inside of the pitch cone,
then they are known as internal bevel gears.
Mitre bevel gears are used in sugarcane harvesting machines because they allow for efficient
power transmission and torque transfer between the engine and the cutting blades. It is designed
to handle high loads, provide smooth operation and helps to ensure reliable and efficient
performance in the field.
Figure 4-0-7 Mitre gears[33]

Material
Carbon steel is selected for bevel gears because it has high strength, good wear resistance, and
relatively inexpensive compared to other materials. Bevel gears are subjected to high loads and
stresses, and carbon steel can withstand these forces without deforming or breaking.
𝑃𝐷 = 𝑃𝑅 ∗ 𝐾1 (4.32)
Where 𝑃𝐷 =Design of power
PR=rated power = 4.6kw
K1= 1.25 for steady and continuous move
Then the design power given as
𝑃𝐷 = 4.6𝑘𝑤 ∗ 1.25 = 5.75𝐾𝑤
47
Assume the velocity ratio is one (VR=1)
𝑇𝐺 𝑁𝑃
𝑉𝑅 = = (4.33)
𝑇𝑃 𝑁𝐺
𝑁𝑃
𝑉𝑅 = = 1, but Np = 2750rpm
𝑁𝐺
2750𝑟𝑝𝑚
= 1
𝑁𝐺
𝑁𝐺 = 2750𝑟𝑝𝑚
𝑇𝐺
𝑉𝑅 = since VR=1
𝑇𝑃
𝑇𝐺 = 𝑇𝑃 = 18 teeth
𝑇𝐺 𝑁𝑃
=
𝑇𝑃 𝑁𝐺
Angle between axes of shaft is 𝜃𝑠 = 90°
𝜃𝑝1 = pitch angle for the pinion
𝜃𝑝2 = pitch angle for the gear
Then; 𝜃𝑠 = 𝜃𝑝1 + 𝜃𝑝2 We can find 𝜃𝑝1 by this formula
1 𝑁𝐺
𝜃𝑝1 = tan−1 ( ) = 𝑡𝑎𝑛−1 ( )
𝑉𝑅 𝑁𝐺
𝜃𝑝1 = tan−1 (1)
𝜃𝑝1 = 45°
48
We can find 𝜃𝑝2 also
θs = θp1 + θp2
θp2 = θs − θp1
θp2 = 90° − 45°
θp2 = 45°
D 2 D 2
Cone distance given as; L = √( G) + ( P) (4.34)
2 2
L = 0.5√(DG )2 + (DP )2
DP = m ∗ TP
DG = m ∗ TG
Where,
m=module
𝑇𝐺 = teeth of gear
𝑇𝑃 = teeth of pinion
𝐷𝑃 = diameter of pinion
𝐷𝐺 =diameter of gear
𝐿 = 0.5√(TG m)2 + (TP m)2 (4.35)
L = 0.5√2(18m)2
L = 12.72𝑚
Because 𝑇𝐺 and 𝑇𝑃 are the same number of teeth
For Mitre No of teeth
𝑇𝑃 For pinion = 𝑇𝑃 sec(𝜃𝑝1 ) (4.36)
𝑇𝑃 = 18sec 45° = 25.45 = 26 teeth
49
To find tooth load ( 𝑓𝑡 )
𝑃𝐷
𝑓𝑡 = (4.37)
𝑉
𝜋∗𝐷∗𝑁
𝑉=
60 ∗ 1000
𝜋 ∗ 18𝑚 ∗ 2750𝑟𝑝𝑚
𝑉=
60 ∗ 1000
𝑚
𝑉 = 2.59𝑚
𝑠
𝑃𝐷
𝑓𝑡 =
𝑉
5.7𝐾𝑤
𝑓𝑡 = 𝑚
2.59
𝑠
𝑁
ft = 2200
𝑚
Assume 20 full depth tooth profile
𝑌 = form factor
0.912
Yp = 𝜋(0.154 −
Tp
0.912
Yp = 𝜋(0.154 −
Tg
Yp = 0.325
Yg = 0.325
𝐿−𝑏
Beam strength 𝑊𝑇 = (𝜎𝑜 × 𝐶𝑟) 𝑏. 𝜋 𝑚. 𝑦′ ( ) (4.38)
𝐿
50
Where
➢ σo = Allowable static stress

➢ Cr = Velocity factor
3
Cr = (3+𝑉) for teeth cut by form cutters
6
Cr =(6 for teeth generated with precision machines
+𝑣)
➢ v = Peripheral speed in m / s
➢ b = Face width b Assume 6m to 7m
➢ m = Module
➢ y' = Tooth form factor (or Lewis’s factor) for the equivalent number of
teeth
➢ L = Slant height of pitch cone (or cone distance)
➢ Selecting carbon steel 0.20%
➢ σo = 196Mpa
➢ Face width b Assume 6m to 7m
➢ Velocity factor (Cr) =0.3
12.72m − 6m
𝑊𝑇 = (196𝑀𝑝𝑎 ∗ 0.3)6𝑚. 𝜋 𝑚. 0.325 ( )
12.72m
𝑊𝑇 = 190.2𝑚2 𝑁
Comparing tooth load 𝑓𝑡 and strength 𝑊𝑇
𝑁
2200 = 190.2𝑚2 𝑁
𝑚
2200𝑁 = 190.21𝑚3 𝑁
𝑚3 = 11.69
m = 2.268mm
51
Take Standard module m=5mm
𝐷𝑃 = 𝑚 × 𝑇𝑝 = 5 × 18 = 90𝑚𝑚
DG= m × TG = 5 × 18 = 90mm
𝑚
𝑉 = 2.59 ∗ 𝑚
𝑠
𝑚
V = 2.59 ∗ 5𝑚𝑚
𝑠
m
𝑉 = 12.95
s
𝑊𝑇 = 190.2 ∗ 52 𝑁
WT = 4755 N
2200
𝑓𝑡 = 𝑁
𝑚
2200
𝑓𝑡 = 𝑁 = 440𝑁
5
L = 12.72 ∗ 5𝑚𝑚
L = 63.6mm
6 6
Now Cr actual 𝐶𝑟 = (6 = 𝑚 = 0.3266
+𝑣) (6 + 12.95 𝑠 )
𝐿−𝑏
For actual values of b min 𝑊𝑇 = (𝜎𝑜 × 𝐶𝑟)𝑏. 𝜋 𝑚. 𝑦 ′ ( )
𝐿
𝑏
𝑊𝑇 = (196𝑀𝑝𝑎 ∗ 0.3266) ∗ 3.14 ∗ 𝑏𝑦′ (1 − )
63.6𝑚𝑚
𝑏
𝑊𝑇 = 316.62b (1 − )
63.6𝑚𝑚
𝐵𝑢𝑡 𝑏 = 6 × 𝑚𝑜𝑑𝑢𝑙𝑒 = 6 × 5 = 30
52
Beam strength Range of b min is 30 to 35mm
bmin = 35mm
WT = 4755N
WT > 𝑓𝑡 𝑠𝑎𝑓𝑒
W
w maximum load for wear
𝐷𝑝 ∗𝑏∗𝑄∗𝑘
𝑊𝑤 = (4.39)
cos(𝜃𝑝1 )
2𝑇𝑔
Where 𝑄 = = 1,𝑘 = 1.92 (4.40)
(𝑇𝑔 +𝑇𝑃 )
90mm ∗ 35mm ∗ 1 ∗ 1.92

Ww =
cos(45° )
𝑊𝑤 = 8553𝑁
Figure 4-0-8 Bevel Gear
53
4.10 Design of gearbox
A gearbox is a mechanical device that is used to transmit power from one rotating shaft to
another. It is used to reduce speed by changing the gear ratio between the input and output shafts.
This allows for more torque to be delivered to the output shaft at a slower speed.
Input power 1.2KW

Input speed 5500rpm
Total gear ratio 20:1
Arrangement; parallel
Number of Stages and Gear Type Selection
While on designing of a gear box a reduction stage of tow would be adequate for a total gear
ratio of 20, from the point of view of using unnecessary additional gears. Therefore, a two-stage
reduction gear box consists of two drivers and two driven gears having a total of four gears. The
number of teeth for each gear can be labeled as T1, T2, T3, and T4 where the subscripts
denoting the respective gear numbers.
𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑜𝑓 𝑡𝑜𝑜𝑡ℎ 𝑜𝑓 𝑑𝑟𝑖𝑣𝑒𝑛 𝑔𝑒𝑎𝑟
𝐺𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜 =
𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑜𝑓 𝑡𝑜𝑜𝑡ℎ 𝑜𝑓 𝑑𝑟𝑖𝑣𝑒𝑟 𝑔𝑒𝑎𝑟
20 = (T2 ∗ T4 )/(T1 ∗ T3 ). (Eq.4.40)
A two- s t a g e reduction can be achieved by taking the factor of the gear ratio to achieve
100% Efficiency which is; 20 = 4 ∗ 5
Therefore, each stage will have a teeth ratio of:
𝑇2
𝑓𝑖𝑟𝑠𝑡 𝑠𝑡𝑎𝑔𝑒 = =4
𝑇1
𝑇4
𝑠𝑒𝑐𝑜𝑛𝑑 𝑠𝑡𝑎𝑔𝑒 = =5
𝑇3
Table 4-1 Table of reduction of gear box[34]
Speed ratio Number of stages
<8 1
8 to 40 2
> 40 3
54
Gear type selection
In order to select the type of gear teeth, we may use the formula of the empirical velocity
given by:
4
𝑉 = 0.11 √𝑃𝑖𝑛 𝑁𝑖𝑛 𝑁𝑜𝑢𝑡 (4.41)
Where p is power in Kw
2𝜋𝑁 2𝜋 ∗ 5500
𝑁𝑖𝑛 = = = 575.67𝑚/𝑠
60 60
2𝜋∗275
𝑁𝑜𝑢𝑡 = = 28.78𝑚/𝑠
60
4
𝑉 = 0.11 √4600 ∗ 575.67 ∗ 28.78
𝑉 = 93 𝑚/𝑠
For values velocity greater than 5 m/s helical gears must be used
Output performance
Input power 𝑝𝑖𝑛 = 4600𝑤 = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 , Input angular speed 𝑁 = 5500𝑟𝑝𝑚
Output angular speed Output torque

60
Input gear ( 𝐺1 ) 𝜏1 = 𝑃 ∗ = 7.99𝑁𝑚
2𝜋𝑁1
𝑁1 = 5500𝑟𝑝𝑚
𝑁1 60
Meshing gear (G2)𝑁2 = 4
= 1375𝑁𝑚 𝜏2 = 𝑝 ∗
2𝜋𝑁2
= 31.96𝑁𝑚
Gear three (G3)𝑁3 = 𝑁2 = 1375𝑟𝑝𝑚 𝜏2 = 𝜏3 = 31.96𝑁𝑚
𝑁3 60
Output gear (G4) 𝑁4 = = 275 𝑟𝑝𝑚 𝜏4 = 𝑃 ∗ = 159.8𝑁𝑚
5 2𝜋𝑁4
The next procedure would be to calculate the minimum number of teeth required on the pinion
gear to mesh with the larger gear without interference, and is given by the equation,
𝑁𝑝 = 2𝑘/(1 + 2𝑚)𝑠𝑖𝑛2 ∅] (𝑚 + √𝑚2 + (𝑚2 + (1 + 2𝑚)𝑠𝑖𝑛2 ∅. (4.42)
55
Where
NP = minimum number of teeth on the pinon to avoid interference
K= a factor depending on the profile of a gear tooth and is equal to 1, for a full depth tooth
m = gear ratio of mating gears
ф = pressure angle and is taken as 20.
First stage in this stage the mating gears are gear 1(pinion) and gear 2, having a designation of
tooth number T1 and T2 respectively.
Np = T1 = 15.93 approximately 16 teeth can be selected
Therefore, from the stage gear ratio the number of teeth on the mating gear can be found as
T2 =4T1
T2 = 64
Second stage
By following similar step as followed on stage one and by substituting the only different
value which is the stage gear ratio
𝑇4
m= =5
𝑇3
Np = T3 =19.83 also can be approximated as 20 tooth

From the stage gear ratio, the mating gear tooth can be found as
T4 = 4T3
T4 = 100
4.11 Design of chain drive

The chain drive is used to transmit the power from one shaft to another due to larger centre
distances between shafts. The chain drive acts as simple gear train and open belt drive as it
transfers the rotation in the same direction as that of driven shaft. It consists of various chain
components such as internal and external components. It is meshed with the sprockets into the
groove between successive teeth.
Material selection:
Mild steel is selected for chain and sprocket because it has good strength, durability, and wear
resistance. It is also relatively inexpensive compared to other materials such as stainless steel or
56
titanium and it can be easily machined and welded, allowing for easy customization and repair of
chain and sprocket components. Material selected: mild steel
Classification of chains
❖ Hoisting and hauling (crane) chains,
❖ Conveyer (or attractive) chains. And
❖ Power transmitting (or driving) chains
From the type of chain for the design we used power transmission chain
Let, N1 = speed revolution of first shaft
N2 = speed revolution of second shaft
Dp = Design power
SF = factor of safety
Design procedure for chain

Step 1: Find Velocity Ratio
𝐺𝑖𝑣𝑒𝑛
𝑁1 = 243𝑟𝑝𝑚
𝑁2 = 81𝑟𝑝𝑚
𝑁1 𝑇2 3
𝑉. 𝑅 = 𝑖 = = = =3
𝑁2 𝑇1 1
Step 2: To find Z (number of teeth)
Based on velocity ratio select the number of teeth on the smaller sprocket Z using table 21.5[35].
𝑧2
At V.R =i=3:1 =
𝑧1
𝑍1 = 15 𝑡𝑒𝑒𝑡ℎ
𝑍2 = 15 ∗ 3 = 45 𝑡𝑒𝑒𝑡ℎ
Step3: Roller chain service factor: drive type on moderate shock.
Rating factor (𝐾3) = 1, 𝑓𝑜𝑟 8 ℎ𝑜𝑢𝑟𝑠 𝑝𝑒𝑟 𝑑𝑎𝑦
𝐾3 = 1.25, 𝑓𝑜𝑟 16 ℎ𝑜𝑢𝑟𝑠 𝑝𝑒𝑟 𝑑𝑎𝑦
57
𝐾3 = 1.5, 𝑓𝑜𝑟 𝑐𝑜𝑛𝑡𝑖𝑛𝑢𝑜𝑢𝑠 𝑠𝑒𝑟𝑣𝑖𝑐𝑒
Design of power = 𝑟𝑎𝑡𝑒𝑑 𝑝𝑜𝑤𝑒𝑟 × 𝑠𝑒𝑟𝑣𝑖𝑐𝑒 𝑓𝑎𝑐𝑡𝑜𝑟

= 1.5 × 4.6 k𝑤𝑎𝑡𝑡
= 6.9 k𝑤𝑎𝑡𝑡
Step4: Using table 21.1 from Gupta select the type of roller chain and its corresponding power
rating (the power that the selected roller chain can handle)[35].
So, for the design the selected number of teeth is 17, and for the chain that we take for conveying
the same gear or sprocket teeth is used.
From table 21.4, we find the corresponding to the pinion speed 100r.p.m. the power transmitted
for chain 0.6B is 0.25KW per stand. Therefore, the chain used to transmit or convey is chain No
0.6. From the table 21.1 [35].
At 0.8B chain type:
𝑃𝑖𝑡𝑐ℎ = 𝑃 = 9.525𝑚𝑚
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑟𝑜𝑙𝑙𝑒𝑟 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 (𝑑1) = 6.35𝑚𝑚
𝑊𝑖𝑑𝑡ℎ 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑖𝑛𝑛𝑒𝑟 𝑝𝑙𝑎𝑡𝑒 (𝑏1) = 5.72𝑚𝑚
𝑇𝑟𝑎𝑛𝑠𝑣𝑒𝑟𝑠𝑒 𝑝𝑖𝑡𝑐ℎ (𝑝1) = 13.92𝑚𝑚
The breaking load

WB= 8.9KW, we know that the pitch number of the gear or sprocket used for conveying: -
180 180
𝑑1 = 𝑐𝑜𝑠𝑒𝑐 ( ) = 𝑐𝑜𝑠𝑒𝑐 ( ) = 5.5𝑚𝑚
𝑇 17
Pitch line velocity of sprocket or gear
𝜋𝑑𝑁 3.14 ∗ 5.5𝑚𝑚 ∗ 81𝑟𝑝𝑚
𝑉1 = = = 23.3𝑚/𝑠
60 60
Load on the chain:
𝑟𝑎𝑡𝑒𝑑 𝑝𝑜𝑤𝑒𝑟 6.9k𝑤𝑎𝑡𝑡
𝑊= =
𝑝𝑖𝑡𝑐ℎ 𝑙𝑖𝑛𝑒 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 23.3𝑚/𝑠
𝑊 = 296𝑁
Step5: Calculate pitch diameter of both sprockets
58
n1=81rpm
n2=243rpm
𝑃 9.525
𝐷1 = = 9.525𝑚𝑚 ≈ 10𝑚𝑚
180° 180°
Sin( ) Sin( )
𝑛1 81
𝑃 9.525
𝐷2 = = = 13.45𝑚𝑚 ≈ 14𝑚𝑚
180° 180°
Sin( ) Sin( )
𝑛2 243
Step 6: Specify the center distance with the recommended range 30-50, let take 30
C = 30* P = 30*9.525mm = 285mm = 28.5cm
Step 7: Compute the required chain length with “C” from step 7
Radius of larger sprocket (R) = 100 mm
Radius of smaller sprocket(r) = 35 mm
C = distance between centres of sprockets =280 mm
𝑅−𝑟)2
Length of chain (𝑙) = 𝜋 (𝑅 + 𝑟) + 2 × 𝑐 + (( ) (4.43)
𝐶
(𝑙) = 3.1415(100 + 35) + 2 × 280 + ((100 − 35)2 /280)
(𝑙) = 999.19 𝑚𝑚 =1000𝑚𝑚
Step 8: Calculate the wrap (contact) angle and check if 1  120

𝐷2 − 𝐷1 14 − 10
𝜃1 = 180° − 2sin−1 ( ) = 180° − 2sin−1 ( )
2𝐶 2 ∗ 285
= 180° − 2sin−1 (0.265) = 171°
⇒ 149.3 > 120°
𝐷2 − 𝐷1 14 − 10
𝜃2 = 180° + 2sin−1 ( ) = 180° + 2sin−1 ( ) = 189°
2𝐶 2 ∗ 285
𝜃2 = 210.74°
Step 9: Calculate the dimensions of the roller chain and sprocket

a. Roller setting radius: ri:
3
𝑟𝑖 = 0.505𝑑1 + 0.069 √𝑑1 . . . . . . . . max
𝑟𝑖 = 0.505𝑑1 . . . . . . . . . . . . . . . . . . . . . . . . . min
3
𝑟𝑖 = 0.505 ∗ 5.5 + 0.069 √5.5 = 2.9𝑚𝑚. . . . . . . . max
𝑟𝑖 = 0.505 ∗ 5.5 = 2.77. . . . . . . . . . . . . . . . . . . . . min
59
b. Roller seating angle  :
90°
140 − . . . . . . . . max
𝑧
90°
120 − . . . . . . . . . min
𝑧
𝑓𝑜𝑟 𝑍1 = 15,
90°
𝛼 = 140 − = 134°. . . . . . . . max
15
90°
𝛼 = 120 − = 114°. . . . … . . min
81
C Tooth height above the pitch polygon (ha)

0.8𝑝
ℎ𝑎 = 0.625𝑝 − 0.5𝑑1 + . . … … … … … … … . … … … … … … … … … … … . . . . max
𝑧
ℎ𝑎 = 0.5(𝑝 − 𝑑1 ). . . . . . . . . . . . . . . . . . . . . . . . . . … … … … … … … … … … … … … . . . . . . . min
𝑓𝑜𝑟 𝑧1 = 25,
0.8 ∗ 12.5
ℎ𝑎 = 0.625 ∗ 12.5 − 0.5 ∗ 8.51 + = 3.9575𝑚𝑚. . … … … … … . . . . . max
25
ℎ𝑎 = 0.5(12.5 − 8.51) = 1.995𝑚𝑚. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . min
𝑓𝑜𝑟 𝑧2 = 75,
0.8 ∗ 12.5
ℎ𝑎 = 0.625 ∗ 12.5 − 0.5 ∗ 8.51 + = 3.691𝑚𝑚. … … … … … … . . . . . . max
75
ℎ𝑎 = 0.5(12.5 − 8.51) = 1.995𝑚𝑚. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . min
D Pitch circle diameter (D):

𝑃 180
D= = 𝑝cos𝑒𝑐( )
180 𝑧
sin( )
𝑧
9.525𝑚𝑚
𝑓𝑜𝑟 𝑠𝑝𝑟𝑜𝑐𝑘𝑒𝑡1 𝐷 = = 10𝑚𝑚
180°
sin( )
15
9.525𝑚𝑚
𝑓𝑜𝑟 𝑠𝑝𝑟𝑜𝑐𝑘𝑒𝑡2 𝐷 = = 14𝑚𝑚
180°
sin( )
45
f. Top diameter (Da):
𝐷𝑎 = 𝐷 + 1.25𝑃 − 𝑑1 . . . . . . . … … … … … … … … … . . . . max
1.6
𝐷𝑎 = 𝐷 + 𝑃 (1 − ) − 𝑑1 … … … … … … … … … . … . min
𝑍
𝑓𝑜𝑟 𝑧1 = 15,
𝐷𝑎 = 10 + 1.25 ∗ 1.25 + 5.5 = 16.56𝑚𝑚. . . . . . . . . . . max
1.6
𝐷𝑎 = 10 + 9.525(1 − ) − 5.5 = 13.19𝑚𝑚. . . . . . . min
15
𝑓𝑜𝑟 𝑧2 = 35
𝐷𝑎 = 14 + 1.25 ∗ 1.25 + 5.5 = 21.06𝑚𝑚. . . . . . . . . . . max
60
g. Root diameter D f = D − 2ri
Take ri =4.3mm=0.43cm……. min
For D=10mm
D f 1 = 10mm − 4.3mm = 5.7mm
For D=30cm
𝐷𝑓2 = 14𝑚𝑚 − 4.3𝑚𝑚 = 9.7𝑚𝑚
Tooth side radius𝑟𝑥 = 𝑝 = 9.525𝑚𝑚
4.12 Wheel selection

Based on the application of the movable small scale sugarcane harvesting machine there should
be 3 wheels to sustain the load and the machine in the straight position and also to move from
one place to another without any obstacle / problem during using the machine. We select two
830×30 size rubber tube tire wheels.
Rear wheel
Diameter of wheel=400mm
Diameter of shaft that inserted to the wheel=30mm
Figure 4-0-9 wheel
61
Front wheel **
Diameter of wheel 150mm
Diameter of shaft that inserted to the wheel=30mm
4.13 Ground wheel

Transportation wheel or ground wheel was the main component of the single row sugarcane
harvester, which were touches on ground surface. This facilitates easy movement of the harvester
in the field. a.
Speed of ground Wheels
The output shaft of the engine was keeping that 5500 rpm for the 1st gear ratio raising 20:1 so,
the speed of the output of the gear box is 275 rpm
𝑁1
Gear ratio of gearbox = (4.4)
𝑁𝑔
Where 𝑁1 is engine speed

𝑁𝑔 𝑖𝑠 Speed of output of gear box;
Gear ratio was 20:1

apply above equation.
Ng = 275rpm Hence the speed
𝑁𝑔 𝑍2
= (4.45)
𝑁𝑊 𝑍1
Where: Z1 = 15=Small sprocket teeth;

Z2 = 45=Larger sprocket teeth;
Ng = speed of the ground wheel shaft; and.
N𝑤 = Speed of the ground wheel.
𝑵𝒈 ∗ 𝒁𝟏 𝟐𝟕𝟓𝒓𝒑𝒎 ∗ 𝟏𝟓
𝑵𝒘 = = = 𝟗𝟏𝒓𝒑𝒎
𝒁𝟐 𝟒𝟓
Therefore, the speed of ground wheel is 91 rpm.
62
4.14 Frame
The dimension of the machine is depending on the designer want, the length of the housing
(frame) depending on the size of the feeder, the feeder length is given by the amount of load
applied, the height of the machine is depending on the height of sugarcane and the width of the
machine is given by considering the sugarcane space rowing place.
Figure 4-10; frame
A frame of mild steel, 1000 mm × 850 mm × 800 mm (length × width × height) is designed.
A Bending moment analysis for the frame
Bending is a major concept used in the design of many machines and structural components like
beams. Analysis and the design of beams i.e., structural members supporting loads applied at
various points along the members.
Suppose the frame was simply supported beam, therefore the bending moment is given in the
following equation.
(𝑊×𝐿)
Bending Moment (BM) =
4
Where, W = Total weight on frame in kg
L = Total length of frame in cm
Loads that are applied to this frame include,
63
Weight of bevel gear = 171.06N
Weight of gear box = 40N
Weight of engine = 68N
Weight of horizontal Shaft = 37.68N
Weight of pulley = 87 N
Weight of bottom cutter = 80N
Weight of upper cutter = 40N
W = 523.74N
𝑊×𝐿
Bending Moment (BM) =
4
523.74𝑁∗1000𝑚𝑚
BM =
4
BM = 130935Nmm
The ultimate stress of the material (Mild steel) was 1000 kg/cm2
We select maximum factor of safety 4.

𝑈𝑙𝑡𝑖𝑚𝑎𝑡𝑒 𝑆𝑡𝑟𝑒𝑠𝑠
Design Stress (or) Working Stress =
𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦
(1000 𝑘𝑔/𝑐𝑚2)
=
4
= 250 *104 pa
Handle
The handle is the external attachment that is used for push and pull of the machine. So, the
material should move easily from one place to another and it should have good strength to do
this work to reduce bending of the material.
64
CHAPTER FIVE
5.1 RESULT AND DISCUSSION
The Result is analyzed by comparing power, small scale harvesting machine and large-scale harvesting
machine. The machine has a capacity to cut 3.75 ton of sugarcane per hour. Comparing with manual
harvesting 50% of harvesting time and 60% of labors are reduced (in manual sugarcane harvesting 15-16
labors are required). The cost of harvesting is reduced by 34% when compare to manual harvesting. When
comparing with the large scale, though the harvesting time and fuel consumption is less in large scale.
Belt
Material: Chrome tanned leather
center distance C=375mm
Length of the belt L = 1339mm
Area of the belt=111.4mm2
Pulley-1
Diameter = 125mm
Face width =25mm
Take number of sheave grooves n=1
Depth d = 6mm
Depth up to pitch line a = 3.25mm
Pitch e = 15mm
Groove angle (2β) in degrees = 32°
Pulley-2
Diameter = 250mm
Face width =25mm
Number of sheave grooves n=1
65
Depth d = 6mm
Depth up to pitch line a = 3.25mm
Pitch e = 15mm
Horizontal Shaft
Material carbon steel of grades 40 C 8
Diameter = 30mm
Length = 750mm
Vertical shaft
Diameter = 25mm
Length = 2000mm
Bearing for horizontal shaft
Bearing number 206
Bore = 30mm
Outside diameter = 62mm
Width = 16mm
Bearing for vertical shaft
Bearing number 4825
Bore = 25mm
Outside diameter = 37mm
Width = 12mm
Bevel gear
Diameter of gear = 90mm
Diameter of pinion = 90mm
Module m = 5mm
66
Face width b = 35mm
Angle of shaft = 90°
Angle of pinion and gear=45°
Lower cutter
Diameter=250mm
Bore= 25mm
Upper cutter (blade)
Diameter= 500mm
Bore=25mm
Chain drive
Radius of larger sprocket (R) = 100 mm
Radius of smaller sprocket(r) = 35 mm
distance between centers of sprockets ( c )=280 mm
length of chain =10000mm
67
5.2 SIMULATION RESULT
Simulation analysis is a powerful tool that can be used to evaluate the performance of various
mechanical components and systems. The SolidWorks simulation tools is used to analyze the
performance of each component and the system as a whole.
5.2.1 Bearing Simulation Analysis
Bearings are used to support rotating components such as shafts. The simulation analysis of
bearings involves evaluating their load-carrying capacity and determining their fatigue life under
different operating conditions.
Name Type Min Max

Stress1 VON: von Mises Stress 0.000e+00N/m^2 5.482e+05N/m^2
at Step No: 1(1 Node: 1 Node: 14001
Seconds)
Figure 5-0-1 bearing -Stress-Stress
68
Name Type Min Max
Displacement1 URES: Resultant 0.000e+00mm 1.676e-03mm
Displacement at Step No: Node: 1 Node: 14570
1(1 Seconds)
Figure 5-0-2 bearing -Displacement-Displacement
69
Name Type Min Max

Strain1 ESTRN: Equivalent Strain at 0.000e+00 2.104e-06
Step No: 1(1 Seconds) Element: 1 Element:
8035
Figure 5-0-3 bearing-Strain-Strain
70
5.2.2 Bevel Gear Simulation Analysis
Bevel gears are used to transmit power between intersecting shafts at right angles. The
simulation analysis of bevel gears involves evaluating their strength and durability under
different operating conditions.
Name Type Min Max

Stress1 VON: von Mises Stress 8.122e+05N/m^2 8.584e+10N/m^2
Node: 41 Node: 356402
Figure 5-0-4 Bevel Gear Stress-Stress
71
Name Type Min Max
Displacement1 URES: Resultant 0.000e+00mm 2.641e+00mm
Displacement Node: 97 Node: 458436
Figure 5-0-5 Bevel Gear-Displacement-Displacement
72
Name Type Min Max

Strain1 ESTRN: Equivalent Strain 4.240e-06 3.117e-01
Element: 231152 Element:
355699
Figure 5-0-6 Bevel Gear -Strain-Strain
73
5.2.3 Frame Simulation Analysis
Frames are used to provide structural support to various mechanical systems. The simulation
analysis of frames involves evaluating their strength and stiffness under different loading
Name Type Min Max

Stress1 VON: von Mises 1.562e+01N/m^2 1.289e+04N/m^2
Stress Node: 7488 Node: 2589
conditions.
Figure 5-0-7; frame-Static 2-Stress-Stress1
74
URES: Resultant 1.260e+06mm 6.296e+06mm

Displacement Node: 4665 Node: 65
Figure 5-0-8; frame-Static 2-Displacement-Displacement1
75
ESTRN: Equivalent Strain 6.236e-11 3.026e-08

Element: 3769 Element:
652
Figure 5-0-9 frame-Static 2-Strain-Strain1
76
5.2 COST ANALYSIS
Table 5-0-1; Cost analysis
No Part name Quantity Cost in birr Total cost
1 Pulley one 1 1000 1000
2 Pulley two 1 800 800
3 Bevel gear 4 1250 5000
4 Shaft 1 2000 2000
5 Vertical shaft 2 700 1400
6 Bearing bore 25 4 300 1200
7 Bearing bore 30 2 400 800
8 Engine 1 50000 50000
9 Lower cutter 2 800 1600
10 Upper cutter(blade) 2 500 1000
11 Wheel 3 3000 6000
13 Belt 1 2500 2500
14 Fuel 2 liter 70 140
15 Bolt 12 73 876
16 Nut 12 43 516
17 Chain 1 4200 4200
18 Sprocket 2 500 1000
19 Helical 4 2629 10516
Total 90548 birr
Total cost 95600 birr
77
CONCLUSION
A small-scale sugarcane harvesting machine was successfully designed and modeled using CAD
software (SolidWorks). The machine consists of an engine, a gearbox, a belt drive, a cutter blade,
and a bevel gear mechanism. The machine can cut sugarcane stalks in the field. The machine can
perform the harvesting operation faster and safer than manual harvesting with machetes. The
machine can reduce labor costs, time, and risks associated with sugarcane harvesting. The
machine can improve the productivity and profitability of small-scale sugarcane farmers or
planters. The machine meets the objectives of this project by designing all the components of a
small-scale sugarcane harvesting machine, selecting proper engines and materials for small-scale
harvesting machines, and modeling 3D of a small-scale sugarcane harvesting Machine by using
CAD software. The machine fills the gaps identified in the literature review by providing a
simpler mechanism for cutting the sugarcane at a faster rate, reducing the manual labor involved
in harvesting, and enhancing the safety of the workers.
78
RECOMMENDATION
The recommendations for this project are:
➢ To conduct further testing and evaluation of the machine in real field conditions to verify
its functionality and reliability. To measure the performance indicators such as cutting
speed, cutting efficiency, fuel consumption, noise level, etc. To compare the results with
manual harvesting or other existing machines.
➢ To explore alternative sources of power or energy for the machine to reduce its
environmental impact and fuel dependency. To consider using renewable energy sources
such as solar panels, batteries, or biofuels. To assess the feasibility and cost-effectiveness
of these options.
➢ To incorporate additional features or improvements to the machine such as steering
mechanism, height adjustment, safety sensors, etc. to enhance its usability and efficiency.
To design a mechanism that can allow the machine to change direction or adjust the
cutting height according to the field conditions. To install sensors that can detect
obstacles or hazards and stop the machine automatically.
➢ To disseminate the results and benefits of the machine to potential users or stakeholders
in the sugarcane industry. To conduct demonstrations or workshops to showcase the
machine and its advantages. To solicit feedback or suggestions from the users or experts.
To promote the adoption or diffusion of the machine in the market.
79
References
[1] P. Action and T. S. Centre, “Sugar Production from Sugar Cane,” vol. 44, no. 871954,
1926.
[2] N. Resources, “COURSE TITLE : INDUSTRIAL CROPS PRODUCTION Course Code :
( Plsc 2063 ) 2 nd year PLSC Semester II Name of Instructor : Amanuel Alemu . ( MSc .
In Agronomy ),” vol. 3, no. Plsc 2063, pp. 1–84, 2020.
[3] Y. A. Zikargie, P. Wisborg, and L. Cochrane, “State-led modernization of the Ethiopian
sugar industry : questions of power and agency in lowland transformation questions of
power and agency in lowland transformation,” J. East. African Stud., vol. 0, no. 0, pp. 1–
21, 2023, doi: 10.1080/17531055.2023.2166449.
[4] H. sugarcane. org. “Spreading the word about clean solutions from sugarcan,” Accessed
04/07/2018, “Ambient Illumination Toggles a Neuronal Circuit Switch in the Retina and
Visual Perception at Cone Threshold,” Neuron, vol. 78, no. 2, pp. 325–338, 2013, doi:
10.1016/j.neuron.2013.02.014.
[5] G. D. Urgesa and E. O. Keyata, “Effect of Harvesting Ages on Yield and Yield
Components of Sugar Cane Varieties Cultivated at Finchaa Sugar Factory ,” vol. 2021,
2021.
[6] T. O. Terefe, “Design And Development Of Manually Operated Reaper Machine,” vol. 1,
no. 2, pp. 15–21, 2017.
[7] K. K. Reddy, ““ FABRICATION OF SMALL SCALE SUGARCANE HARVESTING
Department of Mechanical Engineering”.
[8] R. A. Ballinger, “A HISTORY OF SUGAR MARKETING THROUGH 1974 by Origin
of Cane Sugar,” no. 18, 1974.
[9] “''Ethiopian Sugar Corporation." Wikipedia, Wikimedia Foundation, 26 Aug. 2021,”,
[Online]. Available: en.wikipedia.org/wiki/Ethiopian_Sugar_Corporation.
[10] Ethiopian Agricultural Transformation Agency (ATA) -, “‘Sugarcane Harvester Machine:
A Boon for Ethiopian Farmers’”, [Online]. Available: https://www.ata.gov.et/sugarcane-
harvester-machine-a-boon-for-ethiopian-farmers/
[11] 2003. Meyer, E., Fenwick, L.J., “Manual sugarcane cutter performances in the Southern
African Region. In Proc. S. Afr. Sug. Technol. Assoc. (Vol. 7, pp. 150-157).”.
[12] 2013 Braithwaite, 2013; Tweddle, 2013; Yinggang et al., “Braithwaite, P., 2013.
80
Harvesting and haulage. eds. Meyer, J., Rein, P., Turner, P. Mathias, K., Good
management practices for the cane sugar industry, 355-374”.
[13] T. Tumkuru, R. Assoc, and T. Tumkuru, “Design and Fabrication of Small Scale
Sugarcane Harvesting Machine Fig1 : World Agriculture Equipment Market,” vol. 3, no.
4, pp. 293–298, 2015.
[14] “State of the art : Sugarcane mechanical harvesting-discussion of efforts in Egypt,” no. 11,
pp. 57–68, 2014.
[15] T. (2007) No TAkachi, “Performance and characteristics of the harvester under green cane
harvesting in Okinawa. Proc. Int. Soc. Sugar Cane Technol., Vol. 26, 2007itle”.
[16] Huang L. H. and Wei W. S., “(1989) Development of whole stalk harvester (China)
ISSCT: 1017-1022”.
[17] Scott A (1988), “Development of the centurion whole-st alk cane harvester. ISSCT XIX:
192-201”.
[18] Hudson J. C., “(1978) A system for whole stalk cane harvesting. ISSCT XVI : 1985-
1999.”.
[19] T. C. R. and R. R. N. (1989) Neto V. L. H. Monteiro, “Sugarcane topping process utilizing
mechanical harvesters of chopped cane associated with row materiall quality for payment
purpose. ISSCT XIX: 177-181”.
[20] A. Tambosco N., Teixeira B., Geraldi F. Ustiulin J. Henrique P. and W., “(1978) Trash In
Mechanical and manual Harvesting of sugarcane. Proce. XIV of ISSCT Cong.: 1975-
1979.”.
[21] N. G. and M. S. J. C. (2002) Meyer, E., “Clowes (2002) Trails comparing semi-
mechanized and chopper harvesting methods over three seasons in Swaziland. Proc. S.
Afr. Sug. Technol. Ass.76: 120-134”.
[22] Alison W. F. (1974), “A mechanical harvesting system without burning. ISSCT XV:
1088- 1095”.
[23] Boast M. M. (1985), “progress report on the sasaby whole 5talk cane harvester.
Proceedings of The South African Sugar Technologists’ Association - June 1985: 225-
229”.
[24] E. (1984) T. mid way cane cutter. Meyer, “Proceedings of The South Afican Sugar
Technologists’ Association - Jun,1984:223-226”.
81
[25] Lubis Muzaki (2014) World agricultural products., “http://agrotechno-park.
blogspot.com/2012/04/sugar-cane-harvester-vicro.html”.
[26] A. Yinggang, OU, Malcolm W., Yang D., Liu Q. Z. Dingke, W. M. and L. H. (2013),
“Mechanization technology: The key to Sugarcane Production in China. Int J Agric &
Biol Eng Open Access at http://www.ijabe.org Vol. 6 No.1: 1-27”.
[27] T. K. (1996) Gupta C. P., L. Lwin, “Development of a Self-propelled Single-axle
Sugarcane Harvester. Applied Engineering in Agriculture. 12(4): 427-434. (doi:
10.13031/2013.25667) @1996.”.
[28] L. for Sugarcane and by L. C. Gonzaga, “Land for sugarcane”, [Online]. Available:
https://www.witnessimage.com/stories/bitter-sugar/
[29] Hunsigi and Adarsh J. Jain. s.l. :, “Design and fabrication of small scale harvesting
machine. Vinay thotad, International Journal of Mechanical and Robotics, Vol. Vol. 2.”.
[30] Z. Wolde and A. Adane, “Determination of planting Season of Sugarcane at Kuraz Sugar
Development project , Southern Ethiopia,” pp. 44–49.
[31] V. Environment, “An Engine Selection Framework for High Fidelity Serious Games,”
2010.
[32] Addisu K/mariam, “Design of machine elements II,”
[33] A. K/mariam, “A Textbook of Machine Design by R.S.KHURMI AND J.K.GUPTA
[tortuka],” no. I, 2005.
[34] H. T. Annealing et al., “CONTENTS”.
[35] R.S. KHURMI AND J.K GUBTA, A Text book of machine design.
82
Appendix
Part one : Standard table [35]
Table A-1 dimensions of standard v-belts according to IS:2494-1974
Table A-2 standard pitch lengths of v-belts according to IS:2494-1974
83
Table A-3 density of belt materials
Table A-4 Coefficient of friction between belt and pulley
Table A-5 Recommended value for Km and Kr
84
Table A-6 Values of factor of safety
Table A-7 Design dimensions of screw threads, bolts and nuts according to IS:4218
85
Table A-8 Dimensions of standard v-grooved pulleys according to IS:2494-1974
86
Table A-9 characteristics of roller chains according to IS:2403-1991
Table A-10 power rating (in kw) of simple roller chain
87
Table A-11 life of bearing and principal dimensions for radial ball bearings
88

Jimma University

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Jimma University

Uploaded by

Copyright:

Available Formats

JIMMA UNIVERSITY

JIMMA INSTITUTE OF TECHNOLOGY

Submission Date June 14, 2023

Name Signature Date

Abstract .......................................................................................................................................... iii

List of figures ................................................................................................................................ vii

List of tables ................................................................................................................................... ix

CHAPTER ONE ............................................................................................................................. 1

1.1 Background ........................................................................................................................... 1

1.2 Problem statement ................................................................................................................. 3

1.3 Objectives .............................................................................................................................. 4

1.4 Scope of the project ............................................................................................................... 4

1.5 Significance ........................................................................................................................... 5

1.6 Limitation .............................................................................................................................. 5

CHAPTER TWO ............................................................................................................................ 6

2 LITERATURE REVIEW ......................................................................................................... 6

2.1 The overview of sugarcane harvesting .................................................................................. 6

2.2 Method of harvesting and previous works ............................................................................ 6

2.2.1 Equipment of full mechanization sugarcane harvesting .................................................... 8

2.2.2 Equipment of semi mechanization sugarcane harvesting ................................................ 10

2.3 literature gap ........................................................................................................................ 13

CHAPTER THREE ...................................................................................................................... 14

3 METHODOLOGY AND MATERIAL SELECTION ........................................................... 14

3.2 Material selection ................................................................................................................ 16

3.3 Working principle ............................................................................................................... 19

CHAPTER FOUR ......................................................................................................................... 20

4. DESIGN ANALYSIS ........................................................................................................... 20

4.1 Design consideration ........................................................................................................... 20

4.2 Design of pulley and V belt................................................................................................. 21

4.3 Design of shaft .................................................................................................................... 28

4.4 Design of cutter (bottom cutter) .......................................................................................... 35

4.5 Design of upper cutter ......................................................................................................... 36

4.6 Design of keys and keyways ............................................................................................... 37

4.7 Bearing Selection ................................................................................................................ 39

4.8 Design of bolt and nut ......................................................................................................... 44

4.9 Design of bevel gear ............................................................................................................ 46

4.10 Design of gearbox ............................................................................................................. 54

4.11 Design of chain drive ........................................................................................................ 56

4.12 Wheel selection ................................................................................................................. 61

4.13 Ground wheel .................................................................................................................... 62

CHAPTER FIVE .......................................................................................................................... 65

5.1 RESULT AND DISCUSSION............................................................................................ 65

5.2 SIMULATION RESULT .................................................................................................... 68

5.2.1 Bearing Simulation Analysis ........................................................................................ 68

5.2.2 Bevel Gear Simulation Analysis................................................................................... 71

Figure 2-0-2 Self-propelled whole stalk sugarcane harvester [17] ............................................................... 9

Figure 2-0-3Chopper harvester (sugarcane combine) [19] ......................................................................... 10

Figure 2-0-4 VICRO South African made sugarcane harvester[25] ........................................................... 12

Figure 2-0-5 Walking type sugarcane harvesters in operation [27] ............................................................ 13

Figure 3-0-1; flow chart of methodology .................................................................................................... 14

Figure 3-0-3; 3D model of small-scale sugarcane harvesting machine ..................................................... 19

Figure 4-0-1 Pulley connected whith shaft ........................................................................................... 28

Figure 4-0-2 Reaction force of horizontal shaft .......................................................................................... 31

Figure 4-0-3 Reaction force of vertical shaft .............................................................................................. 33

Figure 4-0-4 Bending moment diagram ...................................................................................................... 34

Figure 4-0-5; standard designations of ball bearings[33] ........................................................................... 41

Figure 4-0-6 bearing connected with shaft ................................................................................................. 44

Figure 4-0-7 Mitre gears[33] ...................................................................................................................... 47

Figure 4-0-8 Bevel Gear ............................................................................................................................ 53

Figure 4-0-9 wheel ...................................................................................................................................... 61

Figure 4-10; frame ...................................................................................................................................... 63

Figure 5-0-1 bearing -Stress-Stress ............................................................................................................. 68

Figure 5-0-2 bearing -Displacement-Displacement .................................................................................... 69