Design & Fabrication of Sugarcane Cutting Machine

SYNOPSIS

India is an agricultural country, In which 70% people are farmers. As, the
population of India is growing, the demand of food is also increasing. Therefore, we
should try to bring more land under cultivation.
Under these circumstances, we are in need of fast cutting process

instead of traditional cutting methods. In past, agri-related activities were taken care by

means of manual force. But now a days in most parts of our country there is scarity of

labours; hence labours are not available when required. So the labour cost is increased as

for cutting of sugarcanes only skilled labours are required.

To minimize the labour cost and to get work done in minimum,

time at cheap cost we have designed “SUGARCANE CUTTER’. It is simple in

construction. It does not need skilled labour.

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 Design & Fabrication of Sugarcane Cutting Machine

“FUTURE ADVANCEMENT”
TROLLEY ARRANGEMENT :
As the designing of the cutters is done on the tractor. But from the

more economical point of view of the middle class farmers, everyone can not effort the

tractor arrangement. So from this view cutter could be mount on the trolley arrangement.

TROLLEY :-

The trolley is some what similar to the trolleys used on the railway

station. A three wheels based trolley is used. A 50 cc two stroke petrol engine is

mounted on the horizontal plate mounted horizontally on the trolley. The cutters are

mounted on the plate parallel to the Engine.

The cutter’s are fitted to the pulley, one is single grooved and

another pulley is double grooved. The cutter’s rotates along with the pulley belted

crossed with the engine.

Specification :-

Material - Mild Steel

Trolley - 31 inch x 17 inch

Height - 37 inch

Wheels – 6 inch in diameter

Plate - 6 mm thick, 36 inch x 3 inch.

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 Design & Fabrication of Sugarcane Cutting Machine

SUGGESTION AND REMARKS IN DIPEX 2003

1. Very useful project for poor farmers but try to minimize it’s costs as much as possible.

2. By this machine/project Indian agriculture will be progress.

3. This instrument is useful for the farmer to cut the foods/grain of the animals. It is

useful for multipurpose use to the farmers in the moral areas.

4. Useful for poor farmer and any development of petrol tank very nice.

5. This machine is useful for the farming and sugarcane producers.

6. Excellent for the farmers . Good project less cost.

7. Good explanation and since it is economic anybody can purchase it easily.

8. Future development is to adjust the cutter height and increase the wheel diameter for

smooth running as per requirement. The it is very useful and labour consuming machine.

9. A very good invention, but suffers from some draw backs which must be improved for

better economic efficiency.

10. It will helpful for saving time and money.

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 Design & Fabrication of Sugarcane Cutting Machine

INDEX

Sr. No. Contents Page No.

1 SYNOPSIS
2 INTRODUCTION 1
3 REVIEW OF LITERATURE 2
4 IMPROVED SUGARCANE CUTTING MACHINE 5
5 DETAILS OF SUGARCANE CUTTING 6
6 DESIGN OF COMPONENTS 8
7 ECONOMICS VIABILITY OF SUGARCANE 16

CUTTER
8 FUTURE SCOPE 17
9 CONCLUSION 18
10 SUGGESTION AND REMARKS IN DIPEX 2003 19
11 REFERENCES 20

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 Design & Fabrication of Sugarcane Cutting Machine

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 Design & Fabrication of Sugarcane Cutting Machine

Chapter-1
INTRODUCTION
In primitive India, agri-related activities were taken care of by manual
means. But in most of the parts of our country, there is a scarcity of labours and hence
labours are not available when required. This gives an opportunity to develop some new
method. So, mechanization of agriculture equipment becomes necessary.
INDIA is the country of farmers and near about 70% of it's Population
depends on agriculture. The History of Indian farmers tells us today how they have
achieved the comfortable position. He acquired the skill of raising crops which provided
food whenever he found good fertile land, he settled down and took to agriculture and
also followed other pursuits of its which made him richer and more comfortable.
As the population Increased food was not sufficient and surplus population
of more on the other areas not so productive. As a result of demand of food is increased,
man is trying to bring and more land under cultivation, under these circumstances we are
in need of fast cutting procedure instead of manual crop cutting.
So we have to adopt mechanical means for the purpose of cutting crops.
This alternative is not only fast but also very cheaper than the conventional manual crop,
cutting.

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 Design & Fabrication of Sugarcane Cutting Machine

Chapter 2
REVIEW OF LITERATURE

2.1 Manual Sugarcane Cutting By Sickle

Generally manual sugar cane cutting involves slicing and tearing action
that results in plant structure failure due to compression, tension or shear. This manual
sugar cane cutting practice is followed by majority of farmers because of socio-
economical and agro-technological reasons. Different types of sickles are used in
different part of country.

2.2 Principle of Sickle

Designs of sickles are based on principles of two types of cutting friction
and shear. It is assume that the cutting action is taken place due to friction when the
knife-edge of the cutter slips around the stalk.
The serrated sickle combines the slicing and sawing action. The Serrated
edge used in cutting devices restricts the sliding action of the plant on the blade for
adequate action of the plant on the blade for adequate cutting. It has been Reported that
sickle with serrated edge do not required the repeated sharpening needed by smooth edge
sickles.

2.3 Single Impact Cutting

Cutting energy as affected by various engine parameters. Cutting energy is
defined as a energy require to cut the plant stem, a process of cutting of stem is done
through shearing action.
Liljeghl (1961) while working with element, of shearing energy suggested
some variables, which affect the energy, required.
The variables are :-

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 Design & Fabrication of Sugarcane Cutting Machine

1] Plant Variables
a] Moisture Content,
b] Maturity of crop
c] Variety of crop.
2] Design variables
a] Thickness of cutter.
b] Speed of cutter
c] Feed roll force.

2.4 Cutter Blade

A] Blade Sharpness :-
The sharpness of blade is an important parameter in cutting process. It was
observed that sharpness is affected power requirements. A blade having Leading edge
thickness less than 0.127 -mm required 35% less energy.

B] Blade Velocity :-
Blade velocity is the another important parameter in cutting process. This
velocity depends upon diameter of blade and no. of RPM. As diameter & RPM are less
the time and force required for cutting will be more and vice- versa and hence optimum
value of diameter & RPM must be taken into consideration.

πDN
V=
60
V = KDN

Where K = π 60

V ∝ DN

Prasad & Gupta (1975) observed that the cutting energy per unity area and
cutting stress were minimum at a velocity between 2.5 to 3.0 m/sec. And optimum value
of velocity was 2.65m/sec.

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 Design & Fabrication of Sugarcane Cutting Machine

C] Dia. of Stem :-
Cutting forces are changed according to the dia. of stem. According to the
category of sugarcane. The strength & diameter of stem varies and thus the Cutting force
also changes.
Diameter of stem = 2.5 cm to 3.0 cm.

D] Determination of Shear Force :-

In contrast to compressive and tensile stress, which cut normal to plane
shear stresses, act parallel to the shearing plane. If tensile and compressive stresses are
act only in one direction the shear stresses but oppose force acting through the centroid of
sections of material are spaced theoretically infinitesimal distance apart.
In practical situation, however the case of a rivet in shear is approximation
of this condition. If the parallel and opposed shearing forces do not lie in a plane
containing longitudinal axis of the body a couple is set up which produces twisting action
termed torsion.
In agricultural material sometime the term shearing has been used for
process which is actually a cutting process and not true shearing.

2.5 Drawbacks in Conventional Sugarcane Cutting Process :-

1] Time require for completing process is more .
2] The farmer cannot get the proper no. of workers at proper time.
3] Loss due to idleness of labour is more .
4] Wages problem arises.
Due to these drawbacks in conventional cutting many numbers of
industries, economists are doing research to solve this problem. Till now crore of rupees
have been spend but new problem arises, as pieces of land in India are small. The
research made by them is not suitable for small agriculturists. Hence they are trying to
fabricate that will suit small agriculturists of India.

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 Design & Fabrication of Sugarcane Cutting Machine

Chapter - 3
IMPROVED SUGARCANE CUTTING MACHINE
In previous article we have discussed the limitation of conventional sugar
cane cutting operations.
Considering this problem we have made the sugar cane cutting machine
with two rotary cutters run by tractor engine. This machine performs the same operation
as that of manual cutting by sawing the labour work.
In this machine, the engine power is transmitted to pulley, which is
directly mounted on the spindle. This speed is transmitted to the cutter through spindle
shafts. By considering the friction loss in the flexible shaft, the speed at both cutters is
near about 1000rpm. (Considering losses in flexible shaft is 5-10%). These losses due to
the friction between can be reduced by the use of proper lubricants.
On both sides of machine the cutters which are rotating are mounted. Both
cutters rotate in same direction. Thus the rotations of both cutters are in such direction so
that cutting operation the tendency of cutters is to throw the sugar cane outward. So after
cutting it will not fall on the frame of the machine.

Principle :-
The working principle of sugar cane cutting is as follows;
It works on the shear cutting principle. When the blade having very small
thickness imparts on a cylindrical surface, the surface gets cut in a plane. The equation
can be written as follows:
F = A x fs
Where, F = Force require to cut the crop in Newton
A = area of shear
fs = Shear stress.
As sugarcane are having their stems of circular cross section.
Therefore, F = π / 4 x d2 x fs

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 Design & Fabrication of Sugarcane Cutting Machine

Where d = diameter of sugarcane stem.

Chapter-4
DETAILS OF SUGARCANE CUTTING
4.1 Sugarcane Considerations :-
The soil and water are two variables, which either have to be suitably
adjusted for the plant to grow. The plant showed be so bred and adjusted that it will adjust
to given soil and water conditions, sugar cane takes one year to matured on the basis of
life of crop. It is known as a seasonal, annual and perennial.
India is a country of small farmers whose holdings are not only small but
fragmented. They carry-out many farm operation with hand tools.

4.2 Parts Description of Sugarcane Cutting Machine :-

4.2.1 Frame :-
Frame is the body of machine which is made of mild steel
(90x690xl6)THK. The frame is of rectangular shaped. Frame acts as a chassis. This is
made by welding the M.S. Plate.

4.2.2 Pulley :-
Pulleys are used to transmit power from driver shaft to driven shaft with
the help of belts.

4.2.3 V-belt :-
V-belt is used to transmit power from driver pulley to the driven pulley V-
belts are advantageous over the other types by it has negligible slip. The design for V belt
is explained in chapter no.5.

4.2.4 Cutter :-
Cutters are used to cut the sugarcane. It is circular in shape. Cutter is of 12
inch (both) in diameter and 3mm in thickness. There are two number of cutters.

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 Design & Fabrication of Sugarcane Cutting Machine

4.2.5 Bearings :-
Bearings are used to support the shafts and to prevent the overhanging of
shaft. These are total 4 in number, bearings used in our assembly. This bearing should be
greased properly. Two are ball bearings, 2 are taper roller bearings, sustaining all types of
loads.

4.2.6 Stepped Spindle :-

Shafts are used to transmit the power. There are 2 shafts in our machine
Both are made in 4 steps. On first step pulley is mounted. On two succeeding steps,
housing arrangement with seal for bearing is made. On last step, cutter is mounted.

4.2.7 Special Purpose linkage :-

The sugar cane cutting machine is attached with the Frame of cultivator by
making the additional T-arrangement. This T-section is bolted with Frame of Cultivator.
Finally the Frame is connected with top link and load link of tractor. The cutter height
from the ground level is adjusted by using hydraulic arrangement, which is in built with
tractor.

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 Design & Fabrication of Sugarcane Cutting Machine

Chapter - 5
DESIGN OF COMPONENTS
5.1 General Design Consideration In Machine :-
Following are the general consideration in designing a machine component.
1) Type of Load and stresses caused by the load.
The load on a machine component may act in several ways due to which
stresses are set-up. The load acting on the frame is the steady loads i.e. the weight of
machine itself. The cutter is acted by various forces. Due to this load and forces internal
stresses are set up.
2) Motion of parts on kinematics of the machine.
The successful operation of any machine depends upon the simplest
arrangement of the parts, which will give the required motion. The machine is capable to
withstand the rotary & vibratory motion.
3) Selection of Material.
It is essential that the designer should have thorough knowledge of
the properties of the material under working condition. The important characteristics of
the materials are strength, durability, weight, resistance of wear and corrosion ability to
cost or hardened machinability. Fro the induced stresses on the components we have
selected the required materials from design data book.
4) Form & Size of part.
Form and size are based on judgment the smallest particles cross-section
may be used but it may be checked that stresses include in the designed cross-section are
safe. On basis of required forces acting on the parts of machine who have designed the
required sizes of arts, which is shown in Chapter 5.
5) Frictional-Lubrication and Resistance.
There is always loss of power due to friction. It is there fore, essential that
a careful attention must be given to the matter of lubrication of all surfaces, which move
in the contact with other. Following are the parts, which requires lubrication.
1. Ball bearings
2. Adjustable cutter arm

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 Design & Fabrication of Sugarcane Cutting Machine

3. Adjustable cutter height

4. Back axle bearing
5. Pulley shaft
Flexible shaft does not require any lubrication.
6) Convenient & Economical Features.
In design ratings features of machine should be carefully studied. The
starting controlling and stopping level should be located on the basis of convenient
handling. The adjustment for wear must be provided expelling various take up devices
and arranging them that the alignment of part is preserved.
7) Safety of Operation.
Some machines are dangerous to specially those, which are up to ensured
production at a maximum rate. Therefore any moving part of the machine, which is
within the zone of the worker, is considered an accident hazard & may lead to injury so
the safety appliances should be used. Likewise for cutter there must be protective cover
to the both cutter which must be adjustable cover.
8) Workshop facility.
A design engineer should be familiar with the limitations of his employers
workshop in order to avoid necessity of having work operation and to draft methods for
casting, handling and machining special parts.
On the basis of material procured from the workshop, operations on .lathe,
welding, grinding, drilling by using tools like hacksaw blade, bastard files, single point
cutting tool the required machine is being fabricated.
9) Number Of Machine To Be Manufactured
The engineering and shaft cost, which are called fixed charges, are
distributed over the no. of articles to be manufactured. And order calling for a small no.
of products will not permit an undo expense in the workshop processes so that the
designer could restrict his specification and standard parts.
5.2 Design as per Sugar Cane Cutting Machine
5.2.1 Design of Pulley (On centrifugal stress consideration )
Designing the pulley on the basis of centrifugal stress consideration.

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 Design & Fabrication of Sugarcane Cutting Machine

let D = Diameter of driven pulley.

N1 = Speed of P.T.O. shaft.
1) We know centrifugal stress
σ = ρ × v2

Assume, tensile stress σ = 0.7 x 106 N/m2

Density of CI, σ = 7250 Kg/m3
0.7 x 106 = 7250 x v2
v = 9.83 m/s
πdN
Velocity of Pulley v =
60
π × d × 1600
9.83 =
60
9.83 × 60
d=
π × 1600
= 0.1173 m
d = 117.3 mm
For power ranges 0.7 - 3.5 kW
Width of belt (b) = 13 mm
Thickness of belt (t) = 8 mm
( Type of belt - A - A - 525 mm long )
2) Width of smaller pulley
The width of smaller pulley or face of pulley (b)
b = 1.25 x k ( k=17, from machine design by Khurmi and Gupta )
= 1.25 x 17
= 21.25
b = 25 mm
5.2.2 Design of Driven Pulley Shaft
Let d= diameter of shaft
N2 = speed of pulley
Power transmitted = 1.119 KW

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 Design & Fabrication of Sugarcane Cutting Machine

RPM of pulley = 1400

We known that torque acting on the pulley shaft
P × 60 1.119 × 103 × 60
T= =
2N2 2 × π × 1400

≅ 8 Nm
Assuming 25 % overload
T pulley = 1.25 x 8
= 10 Nm
Also the axial load on the pulley
2T 2 × 10
ft = =
Dp 0.2

= 100 Nm
and bending moment, M = ft x Dp /2
= 100 x 0.2 /2
= 10 Nm
Now we also the equivalent twisting moment
Te = M2 + T2

Te = [10]2 + [10]2

Te = 14.14 Nm ≅ 15 Nm
This twisting moment is equal to
π
Te = × fS × d 3
16
d = 13.65 mm ≅ 14 mm
Take, d = 19mm (std. Diameter )
Assuming fluctuating load condition, take diameter of shaft = 25 mm and the shaft is
made in step having bearing size 20 mm.
Design of Key
From data book for the range of shaft dia. 22 to 33 key cross section are as
follows :

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 Design & Fabrication of Sugarcane Cutting Machine

i.e. width b = 8 mm
Height h = 7 mm
5.2.3 Cutting Force and Power
We know that the force required to cut is given by
F = Area x Shear stress
Where A = area of sugarcane
& A = π /4 d2
and d = dia. of sugarcan = 30 mm
and considering the shear stress of a sugarcane is 2 N/mm2
Force f = A x fS
= π /4 d2x fS
= π /4 (30)2x 2
= 1413.71 N
This force f is required to cut one sugarcane by one cutter. But our
machine has two cutters and at a time 2- stems are cut
Forced required to cut 2 stems
F=2xf
= 2 x 1413.71
= 2827 .42 N
Therefore power required for cutting
P = force x velocity
1.119 x 103 = 2827.42 x V
V = 0.3957 m/s
= 23.7460 m/min
≅ 25 m/min
Since the velocity of the machine calculated is high. And there are many
difficulties in moving the machine in the field, such as the weight of the machine itself
and the field condition ( including human condition).
Therefore, considering V = 15 m/min = 0.25 m/sec.

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 Design & Fabrication of Sugarcane Cutting Machine

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DET DESCRIPTION MATERIAL QTY. SIZE REMARK

NO.
1 MAIN PLATE MS 1
2 STEEL CUTTER (WOOD -SAW) STD 2 1D32 X OD 300 X 3MM THK
3 DOWEL PIN STD 2 DIA 16 X30 LONG
4 SPINDLE EN-8 2 DIA 80 X 115 LG.
5 WASHER MS 2 DIA 80 X 12 THK
6 SPRING LOCK WASHER STD 2 TO SUIT M20 DIA BOLT
7 ALLEN BOLT STD 2 M20 X 30 LG
8 OIL SEAL STD 2 32 X 52 08
9 ALLEN BOLT STD 8 M10 X 25 LG
10 TAPER ROLLER BEARING STD 2 SKF NO - 30205
11 BALL BEARING STD 2 SKF NO - 6004Z
12 V BELT 'A' SECTION STD 1 A - 525 MM LONG
13 V BELT PULLY A SEC, CI 2 DIA 70 X 25 LG
14 WASHER MS 2 DIA 70 X 25 LG
15 ALLEN BOLT STD 2 M12 X 25 LG
16 HOUSING MS 2 FABRICATED
16A HOUSING BODY MS 2 DIA 65 X 50 LG
16B PLATE MS 2 75 X 115 X 12 THK
17 HOUSING MS 1 DIA 65 X 50 LG WITH DRILL HOLE
18 KEY MS 2 5 X 4 X 20 LG

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 Design & Fabrication of Sugarcane Cutting Machine

Chapter - 6
ECONOMIC VIABILITY OF SUGARCANE CUTTER
Results:
I) The power required for cutting P = 1.11 kW.
II) The force required to cut 2 stems = 2827.42n
III) The cutting speed = 15 m/min
IV) Time required to harvest 1 hector =14.085hrs.

Comparison between Previous Sugarcane Cutting Machine & Improved

Sugarcane Cutting Machine
Previous Sugarcane Cutting Machine Improved Sugarcane Cutting Machine
1. Feed is given by tractor, so skill
1. Manual feed is given so, skill also required is less.
comes into picture. 2. Time required for sugarcane cutting is
2. Time required for sugarcane cutting is less.
more. 3. Power to drive machine is taken from
3. Separate power transmission unit is p.t.o. shaft of tractor.
required, so system is more bulky. 4. Cost of machine is less.
4. Cost of machine is much high 5. More safety in operation.
compared to improved sugarcane 6. Maintenance cost is less.
cutting machine. 7. More versatile in operation.
5. Less safety in operation. 8. Vertical & horizontal movement can be
6. Maintenance cost is more. done with ease & comfort i.e. while in
7. Less versatile in operation. operation the vertical movement of
8. Vertical & horizontal movement of cutter is possible.
cutter is much tidious work i.e. while in
operation we can't change position of
cutters.
Chapter - 7

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FUTURE SCOPE
In present machine there are still modifications to get better results, better
efficiency and easy operation.
Hence we suggest following some modifications.
1) Gear Box :-
In place of direct pulley transmission. If gearbox is used then different
types of speed range are available on the cutter. Gearbox prevents the entry of dirt and
dust particles in the gear.
Also gearbox absorbs the damping and makes the operation noiseless and
hence the life of gear increases.
2) Automotive :-
By giving the same engine power to the wheels by the use of suitable
arrangement the machine can made automotive. Due to this operator does not require to
push the machine and hence he can operate machine easily.
3) Clutch :-
Clutch is used to connect the engine shaft to gear shaft. Thus while
starting the machine clutch is disengaged by operating clutch lever this reduces the load
on engine at the time of starting. Also it is very essential to stop the machine at required
position. Hence by disengaging the clutch machine and cutter stops at required position
without stopping the engine. If this is not done at required time, these create problems
and there are chances of accident, so clutch is very essential in machine.
4) Steering Arrangement :-
By using front wheel castor and giving some steering to it. It is very easy
for operator to turn the machine without lifting, the machine thus it can save the energy
and time of operation.
5) Gripping and collecting Unit :-
While harvesting the major problem arises is that falling of sugarcane on
and in front of machine. This creates problem in operation of machine. So thee must be
auxiliary gripping and collecting unit and that is proposed.
Chapter - 8

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CONCLUSION
On the basis of results from analysis, following conclusion have been
drawn.
1. For rotary cutting blade, higher speed is advantages. Increase in the speed of
rotating cutter causes reduction in chatter losses.
2. The blade speed affects the cutting power and energy i.e. as the speed increases
the power required will be more.
3. The cost of this machine is very less as compared to the manual cutting operation.
Thus it is very economical for the medium class farmer.
4. The machine is simple in construction and is less complicated.
5. For handling this machine is field, the skill required is very less.
6. For performance of machine is good at present level of development.
The cost of automatic sugarcane cutting machine made by Brazil is.152
lakhs. Their labour charge is negligible as compared to India. Hence their sugar rates is 5
Rs/Kg with all taxes and our India sugar is 13 Rs/Kg.
As a result of this they have captured the foreign market. Farmers of India
are not economical to use this machine though it is advanced. Our machine is designed
considering Indian farmer's economy. Therefore it is fruitful to Indian agriculture.

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Chapter - 9
REFERENCE
1 ) Donnel Hunt, "Farm & Machinery Management"
2) Shingley, "Machine Design"
3) Khurmi R.S., "Machine Design"
4) Mahadeevan, "Design Databook"

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