AKSUM UNIVERSITY

AKSUM INSTITUTE OF TECHNOLOGY

FACULTY OF MECHANICAL AND INDUSTRIAL
ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DESIGN AND MODIFICATION OF TEFF THRESHER MACHINE

BSc. Thesis projet by:

Name ID no
1. Muez Gidey AKU1001698
2. Tesfay Kidu AKU1001646
3. Zafu Yohannes AKU1001522

Advisor: Mr. Tedros weldemichael (MSc.)

SUBMISSION DATE 01/10/2016 EC

AXUM, TIGRAY, ETHIOPIA

 DECLARATION

We, the undersigned, declare that the thesis comprises our work. we have acknowledged and
refereed all materials used in this work. We understand that non-adherence to the principles of
academic honesty and integrity, misrepresentation/fabrication of any idea/data/fact/source will
constitute sufficient ground for disciplinary action by the University and can also evoke penal
action from the sources which have not been properly cited or acknowledged.

Name ID no Signature

1. Muez Gidey AKU1001698 ____________________

2. Tesfay Kidu AKU1001646 _____________________

3. Zafu Yohannes AKU1001522 _____________________

Title of the Thesis: Design and modification of teff thresher machine

This thesis project has been submitted for examination with my approval as a university advisor.
Advisor Name: Mrs. Tedros Weldemicael (MSc.)

Signature: _________________________________

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 ACKNOWLEDGEMENT

Before all we would like to thanks to God for helping us to create a great ideas and strength for
the project. Special thanks is perceive to our advisor Mrs. Tedros Weldemicael (MSc.). who
supporting by advising and sharing ideas, information and data to get full information. Next, we
would like to thanks to our Friends’ and dorm mates for giving appropriate comment to our project
progress. Then we want to say thanks to the department of mechanical and industrial engineering
for initiating us to do the project.

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 ABSTRACT

Teff provides over two-thirds of the human food in Ethiopia, with grain protein content (10-12%)
similar to other cereals. In Ethiopia, Teff research to date has focused mostly on breeding and on
improving agronomic practices, Mechanization have not been widely researched; conventional
methods of threshing Teff crop is done on special flat ground called ‘Awidima’ that is usually
plastered by cow dung. Nevertheless, considerable yield losses are incurred while threshing. The
Teff threshing process traditionally is tedious, labor demanding, and most of the time cause of
children out of school while harvest and threshing. Beside to this, as the threshing is done on the
ground, the quality of the Teff crop is affected as it can become mixed with the soil, sand and other
contaminants. This affects the market value of Teff significantly as Teff becomes polluted by the
foreign matter, predominantly minute grains of sand and soil, which are not easy to clean and cause
discomfort for the consumption of people.

Generally, that is why we design and modify teff thresher machine to overcome teff threshing and
cleaning challenges, thereby decreasing tremendous teff grain post-harvest loss because of
traditional method of threshing and cleaning, due to lack of solely threshing machine of this
Ethiopian golden crop.

A thresher is a machine which separates the seeds from the stalk (pinnacle in the case of rice) and
winnows it by means of blower to obtain clean seeds or grains. Threshing involves three distinct
operations: separating the grain from the ear or panicle (the most energy intensive operation);
sorting the grain from the straw; and winnowing the chaff from the grain.

This design helps to find out the typical dimensions of various components of the threshing
machine with great accuracy in small time and also gives fine representation of engine drive teff
threshing machine. Teff threshing machine was designed by using solid works. Mild steel was
used majorly for the fabrication of component parts for ease of machining, assembling,
maintenance and affordability. The machine was evaluated on farm observed to acceptable
threshing capacity and efficiency and the operation cost and quality loss due to traditional
threshing were minimized by far.

Keywords: Teff, Threshing Machine, Design, Power Transmission and Blower

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CONTENTS

DECLARATION ............................................................................................................................. i

ACKNOWLEDGEMENT .............................................................................................................. ii

ABSTRACT................................................................................................................................... iii

CONTENTS ................................................................................................................................... iv

List of figures ................................................................................................................................. ix

List Of Tables ................................................................................................................................ xi

ABBREVIATIONS ...................................................................................................................... xii

ACRONYMS ............................................................................................................................... xiv

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

INTRODUCTION .......................................................................................................................... 1

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

1.2. Problem Statement ............................................................................................................... 3

1.3. Objective of the Project .................................................................................................... 3

1.3.1. General objective ...................................................................................................... 3

1.3.2. Specific objective ...................................................................................................... 3

1.4. Scope of the study ............................................................................................................ 4

1.5. Methodology .................................................................................................................... 4

1.5.1. Primary data gathering .............................................................................................. 4

iv
 1.5.2. Secondary data gathering .......................................................................................... 4

1.6. Working Principle of Teff thresher with blower machine ............................................... 5

1.7. Significance of the study .................................................................................................. 6

CHAPTER TWO ............................................................................................................................ 7

LITERATURE REVIEW ............................................................................................................... 7

2.1. Function of Grain Separation and Cleaning......................................................................... 7

2.1.1. Aerodynamic Separator and Cleaner ............................................................................ 7

2.1.2. Mechanical separation .................................................................................................. 8

2.2. Factors Affecting Separating and Cleaning Efficiency ....................................................... 9

2.2.1. Effect of sieve oscillation and sieve slope .................................................................... 9

2.3 Screening Surface and Recommended Sieve Sizes for Different Grains....................... 14

CHAPTER THREE ...................................................................................................................... 16

DETAIL DESIGN AND ANALYSIS .......................................................................................... 16

3.1 Design Consideration ..................................................................................................... 16

3.1.1. Design of power transmission..................................................................................... 16

3.1.2 Cylinder or Drum (Beater) ...................................................................................... 16

3.1.3 Concave........................................................................................................................ 17

3.1.4 Blower ..................................................................................................................... 19

3.1.5 Sieves ...................................................................................................................... 20

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 3.1.6 Frame ...................................................................................................................... 21

3.1.7 Shaft ........................................................................................................................ 21

3.2 Machine description ............................................................................................................ 23

3.2. Material review .................................................................................................................. 24

3.3. DETAIL DESIGN ANALYSIS ......................................................................................... 26

3.3.1 Design of Drum................................................................................................................ 27

3.3.2 Design of concave ...................................................................................................... 32

3.3.3 Design of Cylinder cover ........................................................................................ 34

3.3.4 Selection of belt ...................................................................................................... 34

3.3.5 Design of Shaft ....................................................................................................... 45

3.3.6 Design of keys......................................................................................................... 53

3.3.7 Selection of sieves................................................................................................... 55

3.3.8 Design of fan (Blower) ........................................................................................... 55

3.3.9 Bearing selection ..................................................................................................... 58

3.3.10 Design of blower cover ........................................................................................... 60

3.3.11 Design of support frame (stand) ............................................................................. 61

3.3.12 Chute ....................................................................................................................... 64

3.3.13 Transport Wheels .................................................................................................... 64

3.4 Assembly procedure ................................................................................................... 64

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 3.5 Principle of operation ..................................................................................................... 66

CHAPTER FOUR ......................................................................................................................... 67

RESULT AND DISCUSSION ..................................................................................................... 67

4.1 Result.............................................................................................................................. 67

4.2 Discussion on the result.................................................................................................. 68

CHAPTER FIVE .......................................................................................................................... 69

COST ESTIMATION ................................................................................................................... 69

5.1 Row material cost ....................................................................................................... 69

5.2 Standard components costs ............................................................................................ 70

5.3 Cost summary................................................................................................................. 73

CHAPTER SIX ............................................................................................................................. 74

CONCLUSION AND RECOMMENDATION ............................................................................ 74

6.1 Conclusion...................................................................................................................... 74

6.2 Recommendation............................................................................................................ 75

REFERENCES: ............................................................................................................................ 76

Appendix A ................................................................................................................................... 79

Part drawing .............................................................................................................................. 79

Assembly Drawing.................................................................................................................... 88

Appendix B ................................................................................................................................... 89

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viii
 List of figures

Figure 1 Teff Plant [28] .................................................................................................................. 1

Figure 2 Traditional Methods of Teff Threshing [29] .................................................................... 2

Figure 3 Diagram of a thresher ....................................................................................................... 3

Figure 4 Method for design of teff thrasher .................................................................................... 5

Figure 5 (a) Teff plant and (b) Teff grain [28]............................................................................. 10

Figure 6 3D ellipsoid model of teff seed [23] ............................................................................... 11

Figure 7 Type of drum .................................................................................................................. 17

Figure 8 Drum beater .................................................................................................................... 17

Figure 9 concave ........................................................................................................................... 18

Figure 10 Blower .......................................................................................................................... 19

Figure 11Sieves and its compartment ........................................................................................... 21

Figure 12 Frame and engine seat .................................................................................................. 21

Figure 13Threshing holding shaft ................................................................................................. 23

Figure 14 Drum beater .................................................................................................................. 32

Figure 15 Concave ........................................................................................................................ 33

Figure 16 Cover plate.................................................................................................................... 34

Figure 17 Belt tensions ................................................................................................................. 36

Figure 18 V belt sections B type ................................................................................................... 39

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Figure 19 V belt and pulley .......................................................................................................... 40

Figure 20 Pulley dimensions ......................................................................................................... 41

Figure 21 Bending moment diagram ............................................................................................ 51

Figure 22 shaft with dimension..................................................................................................... 52

Figure 23 key dimension ............................................................................................................... 54

Figure 24 Key ............................................................................................................................... 54

Figure 25 Sieve ............................................................................................................................. 55

Figure 26 Blower .......................................................................................................................... 58

Figure 27 Standard designations of ball bearings ....................................................................... 59

Figure 28 Bearing dimension ........................................................................................................ 60

Figure 29 Blower cover ................................................................................................................ 61

Figure 30 Supporting Structure .................................................................................................... 64

Figure 31 Assembly drawing of teff thresher with blower machine .......................................... 65

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 List Of Tables

Table 1 Physical properties of Teff [23] ...................................................................................... 11

Table 2 Measured dimensions of Teff grain at different moisture content [23] ........................... 12

Table 3 Specification of Teff Chaff Sample ................................................................................. 12

Table 4 Recommended sieve opening [2] ..................................................................................... 14

Table 5 Basic specification of V belt section specification of V belt section [12]. ...................... 16

Table 6 Belt Material .................................................................................................................... 35

Table 7 Mechanical properties of steel shaft ................................................................................ 46

Table 8 Correcting Factor ............................................................................................................. 47

Table 9 Adjusted inlet area at different rpm to keep constant 3.2m/s at fan exit ......................... 57

Table 10 Principal dimensions for radial ball bearing. ................................................................. 59

Table 11 Relation between equivalent Length (L) and actual length (l) ...................................... 62

Table 12 Result .......................................................................................................................... 67

Table 13 Raw material ................................................................................................................. 69

Table 14 Cost of standard component ......................................................................................... 72

Table 15 Summary of cost ............................................................................................................ 73

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 ABBREVIATIONS

EATA Ethiopian agricultural transformation agency

ECSA Ethiopian central statistical agency

EIAR Ethiopian institute of agricultural research

AAMR Asella Agricultural Mechanization Research Center

ANOVA Analysis of Variance

ASME American Society of Mechanical Engineers

CBA Conveyer Belting Australia

EATA Ethiopian Agricultural Transformation Agency FR Feed Rate

IMP Iranian Ministry of Petroleum

LCC Loren Cook Company

LSDT Least Significant Difference Test

MOG Materials Other than Grain

OARI Oromia Agricultural Research Institute

RPPC Rajendra Pulley Pedestal Centre SGA2000 Sasakawa Global Africa 2000

SO Sieve Oscillation

SS Sieve Slope

TGM Thousand Grain Mass

USDA United State Department of Agriculture wb wet basis

xii
WDM Weight decision matrix

WFP World food program

xiii
ACRONYMS

Symbol meaning

Ans answer

ETB Ethiopian birr (currency)

Fr Actual radial bearing load (N).

g Acceleration due to gravity

Kb Suddenly applied load for bending

No preloaded bearing

Kr outer race fixed inner race rotating

Reliability

Moderate shock load

Kt Suddenly applied load for torsional

Length of correction

Length of pulley

L10 life of bearing

M (max) Maximum bending moment

Vertical bending moments at point A

Horizontal bending moment

xiv
 Vertical bending moments at point D

Mass of crop

Moisture content wet bases

Mass of cylinder

Mass of pulley

Vertical bending moment

Torsion moment

N Speed, Rpm (revolution per minute)

P power

P equivalent dynamic bearing load (N);

r Radius of the object

T Rotational torque

1 Tension in tight side

2 Tension in slack side

Centrifugal tension

Twisted moment

′1 Tension in tight side for lead screw

′2 Tension in slack side for lead screw

V volume

xv
V velocity

Vd Volume of thread

Velocity ratio

Vs Volume of shaft

VT Total volume of lead screw

1 Weight of pulley one

2 Weight of pulley two

Dried weight of sample

Initial weight of sample

Weight of pulley

xvi
 CHAPTER ONE

INTRODUCTION
1.1. Background

One of the economical cereal crops in Ethiopia is teff. It is indigenous to the country, and is
fundamental part of the culture, tradition, and food scarcity of the people. This crop is gaining
international recognition and acceptance, and is a means of foreign currency earning in addition to
its value as food and industrial crop at home. Currently, teff is grown approximately 2.80 million
hectares of land which is 27% of the land area under cereal production. Teff accounts for about a
quarter of the total cereal production and is highly economical food grain in Ethiopia.
Approximately, 6 million households grow teff and it is the dominant cereal crop in 30 of the 83
high-potential agriculture [3].

The potential of teff as raw material for new food products development is high due to its protein
composition; it is gluten free and has a very high-quality amino acid composition. Teff protein is
comparable with that of egg, an ideal protein for children between two and five years of age. It has
been demonstrated that teff starch has a low glycemic acid, and has a mineral composition better
than other cereals [6].

Figure 1 Teff Plant [28]

Against all the odds, the Ethiopian farmers prefer to grow teff because it tolerance to low moisture
stress, water logged and anoxic conditions being better than maize, wheat, and sorghum. Cattle
prefer to feed on teff straw rather than any other cereal straws. Moreover, teff as grain has highest
market prices than the other cereals; this includes both grain and straw, and the grain is not attacked
by weevils during storage. Doubling both the grain and the straw yield of teff would significantly
contribute to Ethiopia’s economy and food security. Techniques being explored to achieve these

1
include not only increasing area under teff cultivation but also using appropriate mechanization
technologies.

Figure 2 Traditional Methods of Teff Threshing [29]

A threshing machine or thresher is a piece of farm machine that threshes grain, which removes the
seeds from the stalks and husks. Threshing is an integral part of post-harvest activities for cereals
and legumes crop. In many developing countries, threshing is carried out by traditional methods
and by using threshing machines. The traditional methods of threshing teff are pounding in mortar
with pestle, beating with clubs on the floor, rubbing on the floor, beating gently With clubs in jute
bags and threading under the feet of man or hooves of animals. In Ethiopia, the most common
method employed by farmers, to thresh teff is spreading the crop over a prepared floor and beating
it with a stick repeatedly. The other widely used method of threshing is trampling by animals. In
both cases, a circular plot of land, called ‘awudma’, 4 to 6 meters in diameter is cleared from
grasses and plastered with thin layer of fresh cow-dung on which the harvested crop (wheat or
barley) is spread for beating or trampling to thresh and also teff winnowing, separation and
cleaning i.e. removal of undesirable materials, is accomplished manually by tossing the grain into
air and letting the wind do the separation and cleaning, removal of lightest impurities, leaves and
large amount of debris with certain amount of grains or grains. For further cleaning is usually done
using sieves to remove the heavy particles and dirt A thresher is a machine which separates the
seeds from the stalk (pinnacle in the case of rice) and winnows it by means of blower to obtain
clean seeds or grains. Threshing involves three distinct operations: separating the grain from the
ear or panicle (the most energy intensive operation); sorting the grain from the straw; and
winnowing the chaff from the grain. The threshing can be achieved by three methods: Rubbing
action, Impact and Stripping.

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 Figure 3 Diagram of a thresher
1.2. Problem Statement

The traditional method of threshing, blowing and handling of teff are labor intensive and time
consuming. In addition to this, these methods are usually lead into contamination of the product
with stones, sticks, chaff, dirt and dust. In addition to this the traditional threshing process takes 4
up to 6 days.

Therefore, the grain, after threshing and blowing cannot be stored or used for consumption due to
this poor physical condition and quality also it takes so many effort and time. To alleviate the
stated problems, we would like to design and fabricate an appropriate teff thresher with blower
machine which can thresh and separate undesired material from the required grain.

1.3. Objective of the Project

1.3.1. General objective

The objective of this project is design and modification of teff thresher with blower machine.

1.3.2. Specific objective

The Specific objectives of this study are:

 To design shaft, blower, drum, sieves and frame of thresher.

 Cost estimation for the manufacturer
 Draw part of the machine by using solid work and assembling of machine

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1.4. Scope of the study

The scope of this project is to solve the problem of threshing, blowing and handling teff in rural
area of our country. This project is start with the literature review on product specification in order
to satisfy the project objectives. The design includes material selection, working principle,
dimension analysis, power and force requirement for threshing and blowing of teff, part design,
component selection and modeling of each part by using solid work software and the project will
focus on design of teff thresher with blower machine.

1.5. Methodology

This research will explain the major methods used to solve the problems that are identified in the
statements of the problem. Therefore, this research planned to address the problems in different
ways

1.5.1. Primary data gathering

We gather and collect information about a teff thresher with blower machine and other related
cereal thresher (such as rice, wheat and maize), and its component through observation.

1.5.2. Secondary data gathering

We have also gathered data and information about teff thresher with blower machine by interview
and reading different books journals.

Analysis of the components: - analytical design of components of teff thresher with blower
machine takes place.

Modeling: We model our design using solid work software.

4
 Figure 4 Method for design of teff thrasher

1.6. Working Principle of Teff thresher with blower machine

A 7.76 - 8.57 hp diesel engine provided the power required to operate the machine during the entire
work. The universal shaft transfers power through belts-pulleys transmission system to the
threshing, separating and cleaning part. The machine threshes the teff crop by hammering action.
The teff is fed by manually pushing teff stack into the hopper and then into the threshing cylinder
of the thresher. The cylinder/Drum/ rotates anticlockwise, beat the stack until it is threshed. The
knife part on the top cover and used to chop the stack to the required size straw and chaff as well
as protect the stack of teff not to wound on the drum of the thresher. At the end length of the drum
or beater there is scooper that scoops and throw chaff and straw through the chaff out let. Both,
the separated grains and chopped straw passed through the concave gates and fall onto the sieves
(Since the broken stack/straw/is heavier than teff crop). The tossing action of oscillating sieves
separate grain from larger straw chaff and allowed them to fall onto small hole-mesh sieve
underneath. The grains were further cleaned from small straw pieces and debris by air coming
horizontally from a small blower (fan) across mixture of grain and material other than grains
(MOG). Finally, Teff grain drops to the delivery unit to be collected.

5
1.7. Significance of the study

Teff thresher with blower machine will bring/contribute a lot of benefits to the society, job seekers
as well as to the country over traditional method.

I. To the society:

 By reducing labor cost and time consumption (to farmer);

 For reliable and quality production of teff grain;
 A farmer will maximize their profit by selling quality teff product;
 To reduce children out of school while harvesting and threshing.

II. To job seekers:

 Create job opportunity (they will manufacture and supply these machine)
 To generate sustainable income.

III. To country:

 To reduce foreign currency by reducing importing thresher machine;

 Increase growth of the county.

1.12. limitation of the study

 Challenges in threshing technology generation and development.

 Limited emphasis given agricultural mechanization research.
 Lack of full agricultural mechanization document in our region.
 Challenges in threshing technology multiplication to limited capacity.
 Challenge in threshing technology delivery system.

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 CHAPTER TWO

LITERATURE REVIEW
2.1. Function of Grain Separation and Cleaning

It is well recognized that grains are the most important input for agricultural production and they
carry important genetic information of which the desirable types can be expressed under well-
organized production knowhow. However, the benefits of good crop varieties cannot be realized
without the availability of clean seeds to farmers. Furthermore, clean seeds of improved varieties
need to be maintained under specific conditions to produce quality grains by farmer.

The function of grain separation is to remove/separate grain from unwanted materials such as
broken and yet short straw, pieces of broken ears (cobs) and chaff. The function of grain cleaning
is to eliminate foreign or undesirable material such as twigs, leaf and soil particles, empty and
weed seeds, dust, chaff and the like to reduce bulk, improve storability and make grains easier to
handle during subsequent processes. The ideal cleaned grain is free from any other materials. The
degree to which this is achieved is called the purity (cleaning efficiency), usually measured in
percentage [16]. Cleaning refers to separation of contaminants from produce and complete removal
of the contaminants so that the cleaned produce is free from re-contamination [8].

Separating process fraction the grain lot into two categories, one category containing the grain and
the other containing inert matter like stem, leaves, dust, dirt, chaff, etc. to be discharged. There are
methods that may separate the grain lot into several fractions with various purities. Intermediate
fractions typically contain both grains and inert matter and must be further cleaned [16].

Basically, undesirable material can be separated from the grain if it differs in its physical
characteristics such as size, shape, weight/mass and density or specific weight. And the more
similar the impurities are to the grains, the more difficult they are to remove/separate. Variation in
grain size and morphology of the grain adds another constraint to grain cleansing.

2.1.1. Aerodynamic Separator and Cleaner

[12], pointed out that threshed grains require considerable additional cleaning before it can be used
as food, whole or ground and even as grain. Pneumatic (aerodynamic) cleaning is the process of
using air to lift light, chaffy and dusty materials out of the grains while heavier materials move
downward.

7
For aerodynamic separation to occur, the particles in a mixture must be accelerated as free
dispersed bodies and not as a mat. Aerodynamic separation depends upon the existence of a
differential between suspension velocities (terminal velocity) of the components to be separated.
Aerodynamic separator and cleaner use air as a medium to lift light materials such as chaff and
dust out of mixture of grain and undesirable materials; i.e. heavier materials moving downward
while light materials are blown away. Air current, either to blow or suspend lighter materials, is
generated by natural or mechanical fan. However, the limitation of natural air current as a means
of separation is the unpredictability in direction, speed and continuity of the air current (wind), and
the high labor requirement and rather imprecise degree of separation [30].

Aerodynamic separators and cleaner are basically of two types, namely the vertical air stream and
horizontal air stream separators [5]. In the vertical air stream separator, air stream is flowing
vertically against the injected mixed product such that heavy particles drop through the air (counter
current flow) while the light materials move upward and are carried along by the air (concurrent
flow). In the horizontal air stream separator, air is blown horizontally or at an inclined angle to the
horizontal against mixed product injected along the vertical plane. The mixed products are
displaced along the horizontal plane at various distances based on their aerodynamic properties.

2.1.2. Mechanical separation

In mechanical separation mixed materials are moved over a perforated and oscillating surface with
openings of specified shape and size. Mechanical or sieve separation is a process separating the
desired material/grain from undesired materials on the basis of differences in sizes and shapes.
Multi sieve separators are used for classifying grains to size grades.

Nonetheless, presence of short straws creates problems by blocking sieve openings and thereby
reduces the quality of final product. Segregation and separation take place along the sieve length
as grain and MOG are being transported over the sieve. The thickness and looseness of the grain
and MOG layer on the sieve influences separation [5]. The process of separation is ensured by the
relative movement of layers of grain and undesired materials caused by the oscillation of plain
sieves. Combination of aerodynamic and mechanical Combined air and sieve system, used to
separate grain from undesired materials, employs terminal velocity, size, shape, and density as a
means to segregation and separation. The method is advantageous and effective than the others
methods of separation. The primary method of grain separating and cleaning, at the moment, is the
air-sieve separator. The physical parameters affecting the separating and cleaning process are
grouped into two:

(i) crop factors that include crop variety, maturity stage, grain moisture content, straw
moisture content, bulk density of grain, bulk density of straw, stalk length, terminal
velocities of particles (both grain and other materials), grain size and

8
 (ii) machine factors such as frequency of sieve oscillations, amplitude of oscillation, sieve
slope, length of sieve, width of sieve, sieve hole diameter, fan speed, angle/direction of air
flow.

2.2. Factors Affecting Separating and Cleaning Efficiency

Separation and cleaning machine have been evaluated using parameters such as separating and
cleaning efficiencies and losses associated with separation and cleaning loss. Machine based factor
such as sieve oscillation, sieve slope and feeding rate, and crop-based factor such as physical
properties and aerodynamic properties were considered to affect the performance of the machine.

2.2.1. Effect of sieve oscillation and sieve slope

Sieve slope, sieve oscillation and air speeds were the main factors that affect separating, cleaning
and total losses. Both separating and cleaning efficiency and total loss increased with increasing
air speed, sieve tilt angle and sieve oscillation. Cleaning efficiency and total losses were seriously
affected by air speed, and sieve tilt angle. The slope of the sieve was the main factor that had a
great effect on separation efficiency. The separation efficiency increased significantly with
increase in sieve slope at small stroke length and decreased at high stroke lengths. In general, there
was decrease in cleaning efficiency with increasing sieve oscillation frequency along the sieve
length. The decrease in cleaning efficiency with increasing sieve oscillations may be due to less
resident time of materials to be separated on the sieve.

Effect of feeding rate

Inverse relationships had been reported between separating and cleaning efficiencies and feed rate.
Decline in efficiency has been a common phenomenon with increasing feeding rate. The inverse
relationship between cleaning efficiency and feed rate was indicated be due to the increasing load
on the sieve that restricted free movement of grains and undesired materials. Cleaning efficiency
of 40.13 % at the feed rate of 120 kg/hr while the same efficiency declined to 36.83 % at the feed
rate of 600 kg/hr. Cleaning efficiency and total losses were affected by increasing feed rate when
cleaning rice at higher feed rate, it required greater sieve length and took longer time for the grain
to be separate from MOG. This was considered to be due to the denseness of the MOG, which
makes diffusion of the grain through it very difficult. The increase in cleaning loss with increasing
feed rate was indicated to be due to high intensity of load with MOG on the sieve that had matting
effect on the sieve and possibly blocked sieve holes. Increasing material feed rate also increased
the total head on the fan leading to a reduction in air velocity from the nominal value. Separation,
at low feed rates with cereal grains and large grains, is primarily aerodynamic, and losses are
usually small.

Crop factors
9
Physical properties of teff grain and straw

There are different teff varieties with different colors varying from white to dark brown. For most
varieties, the plant height is about 50-120 cm (Fig. 2.1). One teff plant is capable of producing
about 9000-90,000 grains, depending on the variety and production conditions. The seeds are small
and oval shaped (length: 0.9-1.7mm; diameter: 0.7-1.0mm). Three thousand teff grains have a
mass of approximately one gram. Compared to wheat, the mass of the teff grain is only 0.6-0.8%.
The seeds of the teff plants are probably the smallest among cereals, with hundred kernels
weighing from 0.18 up to 0.38 mg.

Figure 5 (a) Teff plant and (b) Teff grain [28]

Physical and mechanical properties of grains such assize, shape, density, coefficient of friction,
tensile and compressive strengths are important parameters and be measured or estimated in order
to design separating, cleaning, sizing and grading machines. Measured and/or calculated average
diameter (based on major and minor axis diameters), arithmetic and geometric mean diameters,
equivalent diameter, thousand grain weight (TGM), coefficient of friction on different materials,
and density of teff grains (Variety- Dz Cr- 196) within the moisture range of 11.94 to 27.10 %
(wb) Model of the Teff seeds shape was based on the similarities with ellipsoid.

10
 Figure 6 3D ellipsoid model of teff seed [23]

Table 1 Physical properties of Teff [23]

Moisture content (%, TGM (gr) Coef. of friction, μ (on particle Density (kg/m3)
wb) mild steel)

11.94 0.2920 0.41 1361.82

15.10 0.3201 0.50 1358.22

21.10 0.3609 0.66 1314.85

24.20 0.3918 0.58 1283.67

27.10 0.4207 0.52 1252.91

11
 Table 2 Measured dimensions of Teff grain at different moisture content [23]

Moisture Major dia. L Minor dia. w Average dia. Geo. Mean Equivalent
content (L1+2w2)/3
(mm) (mm) dia. . dia.De (mm)
2
(%, wb) (mm) (Lxw )1/3(mm)

11.94 1.14 0.54 0.74 0,69 0.74

15.10 1.15 0.56 0.76 0.71 0.77

21.10 1.36 0.61 0.86 0.80 0.87

24.20 1.38 0.62 0.87 0.81 0.84

also estimated the diameter and mass of node free, middle nodded and end nodded straws with
different lengths (Table 3).

Table 3 Specification of Teff Chaff Sample

Straw length Node free Middle node End node

(cm)

Mass(g) Dia. (mm) Mass(g) Dia. (mm) Mass (g) Dia.(mm)

1 0.008 2.250 0.021 1.220 0.014 1.590

2 0.014 2.260 0.023 1.520 0.016 1.770

12
 4 0.025 1.610 0.028 1.830 0.026 1.650

6 0.029 1.630 0.032 1.760 0.032 1.810

8 0.034 1.870 0.060 1.712 0.061 1.720

10 0.058 1.670 0.640 1.880 0.063 1.830

[27] indicated that length, width, equivalent sphere diameter, and TGW of teff increased from 1.01
to 1.27 mm, 0.59 to 0.68 mm, 0.71 to 0.87 mm and 0.257 to 0.421 g, respectively, with increase
in moisture content from 5.6% to 29.60% (wb). The spheroid decreased from 0.70 to 0.63 with
increase in the moisture content from 5.60% to 21.43% and increased to

0.69 with further increase in moisture content to 29.60%. The bulk and true densities decreased
from 840 to 696 and from 1361 to 1207 kg/m3, respectively with increase in moisture content from
5.60% to 29.60 % (wb). The porosity and angle of repose increased, respectively, from 38.31% to
42.32% and 23.741° to 51.161° with increase in moisture content from5.60% to 29.60% (wb). The
coefficient of static friction increased from 0.29 to 0.50, 0.36 to 0.51, and 0.18 to 0.48 on mild
steel, plywood and glass, respectively, with increase in moisture content from 5.60% to 29.60%
(wb).

Aerodynamic properties of teff grain and straw

[31] indicate that separation of a product from its associated and yet undesirable materials, such as
straw and chaff, in air stream, require knowledge of aerodynamic characteristics of all the particles
involved. Furthermore, it was noted that a range of air velocities, for effective separation of the
grain from MOG need to be estimated. As such, the terminal velocity (Vt) be used as an important
aerodynamic characteristic of materials in pneumatic conveying and separation.

[24] and [26] noted that by defining the terminal velocity of different threshed materials, it was
possible to determine and set the maximum possible air velocity in which MOG can be removed
without losses.

[23] found the terminal velocity of teff grain to increasing from 3.24 m/s to 4.04 m/s with
increasing moisture content from 11.94 % to 27.10% (wb). On the contrary, he noted that the drag
coefficient was decreasing f r o m 0.76 to 0.66 with increasing in moisture content from 11.94 %
to 27.10 %.

13
Similarly [27] found that the terminal velocity of teff grain was increasing linearly from 3.08 to
3.96 m/s with increasing in moisture content from 6.50% to 30.10% (wb) while the drag coefficient
of teff grain decreased from 0.83 to 0.65 with increasing in moisture content from 6.5 to 30.1 %
wet basis (wb).

Short straws are the major contaminant of threshed materials; they are very difficult to separate
from the grain. Straws are neither symmetrical nor uniform, in density, and their lack of symmetry
causes aerodynamic instability. The terminal velocity of both node-free and middle-nodded straws
of teff decreased from 3.69 m/s to 2.13 m/s and 3.08 m/s to 1.70 m/s, while the terminal velocity
of end-nodded straw increasing from 3.32 m/s to 5.40 m/s with straw length increasing from 1 to
10 cm[26]. Complete theoretical separation of teff grain from straw using air current only is not
possible particularly when end-nodded straws have terminal velocities close to or even greater than
that of teff grains ([27]; [23]).

2.3 Screening Surface and Recommended Sieve Sizes for Different Grains

The basic sieve for cleaning elongated grain is a slotted top sieve and a slotted bottom sieve. In
special separations it may be necessary to pass such grain through round-hole top sieve or over
some sieve other than a slotted bottom sieve, but generally, slotted top and bottom sieves are used
[21].[2] recommends different sieves for different crops (Table 4).

Table 4 Recommended sieve opening [2]

No. Crop Screen opening in mm

Top Screen Middle Screen Bottom Screen

1. Wheat 10r, 9r, 4s,4.5s,6.35r 2s,2.25s

8r,6.5r

2. Barley 14r,10r 4.5s, 3.5s 1.7s, 1.4s

14
 3 Soybean 12r 8r 2.5s

4 Sorghum 6r,7r 4.25s, 4.5s 1.7s, 2s

5 Haricot bean 10r 6.5s 2.75s

6 Teff 2r 1s 0.56s, 0.5s

7 Maize 14r 12r,10r 8r, 6r

8 Rape grain 4r 2.5s 1s

where r stands for round, s stands for slotted

Material screening on sieves with oscillatory motion is a complex process, influenced by a wide
range of factors, related both to the physical properties of the material subjected to screening, as
well as to the geometry of the separation system and its kinematic and functional parameters. Thus,
the understanding of the angle of internal and external friction of grains on the separation surface,
their density, shape of material particles (of grains), grains size, content of impurities in grain
mixture, etc. are important [25].

15
 CHAPTER THREE

DETAIL DESIGN AND ANALYSIS

3.1 Design Consideration
3.1.1. Design of power transmission

The power transmission systems used in the design of machine are belt and pulleys, sprocket
wheels and chain, shaft, gears, universal joints and clutches. Among flexible machine elements,
perhaps V-belt drives have the widest industrial application. Hence, one or more V- belts may be
used on a drive, as required, to transmit power because of their simplicity and ease of design,
selection, installation, maintenance and repair and their low cost. The standard V-belt sections are
A, B, C, D and E. The Table 5 contains design parameters for all sections of V-belt. The kW rating
given for a particular section indicates that belt section selection depends solely on the power to
be transmitted, irrespective of number of belts used. If the required power transmission falls in the
overlapping zone, then one has to justify the selection from the economic view point also [12].

Table 5 Basic specification of V belt section specification of V belt section [12].

Section KW Range Minimum Pulley Pitch Dia. (mm) Width (mm) Thickness (mm)
A 0.4-4 125 13 8
B 1.5-15 200 17 11
C 10-70 300 22 14
D 35-150 500 32 19
E 70-260 630 38 23

3.1.2 Cylinder or Drum (Beater)

The threshing drum is the most relevant part of the thresher. This component beats the crop to
release seeds or grains. This action is accomplished by beating the crop against the concave. The
speed of the thresher is determined by the pulley of the thresher with respect to the diameter of the
drive motor/engine.

16
The drum/cylinder is constructed of mild steel plate rolled into a perfect cylinder with a designed
diameter and length. Iron rods will weld in rows to the body of the cylinder to serve as the spikes.
The iron rods were made from deformed round bar 10mm in diameter 62mm long and chaff
scupper at the out let side which used to throw as well as blow the chaff. The peg type or rasp bar
drum is best to thresh teff, chop the chaff as required for animal feed and plastering residence and
also separate the grain from the chaff so that allow the grain to fall down to the concave. The drum
helps to spike the pods against the concave in order to separate the grains.

Three different cylinders used for threshing different crops are the spike tooth, the rasp bar and the
angle bar as shown below. In the spike tooth type, spikes are mounted on the periphery of the
cylinder. Also in a rasp bar type, corrugated bars are mounted axially on the periphery of the
cylinder while in the angle bar type, cone shaped bars are mounted on the periphery of the cylinder
at an angle of 60-70°.

Figure 7 Types of drum

Figure 8 Drum beater

3.1.3 Concave

17
Concave part is used to house the drum (beater) from the bottom side of the threshing part which
was made up of flat iron, deformed round bar of diameter 8mm, 4mm×40mmx40mm angle iron
and sieve 5mm diameter hole also used to give opportunity for grain not to go with chaff at out let
end. The concave was also made to have choppers which were made from flat iron and sickle
shapes prepared from sheet

metal of 1.5mm to assist the chopping action then after decreasing the wounding opportunity of
the straw on the threshing drum and chop the chaff to the required.

Figure 9 concave

It is a Combination of Aerodynamic and Mechanical system. Combined air and sieve system, used
to separate grain from undesired materials, employs terminal velocity, size, shape, and density as
a means to segregation and separation. The method is advantageous and effective than the others
methods of separation. The primary method of grain separating and cleaning, at the moment, is the
air-sieve separator [2].) The physical parameters affecting the separating and cleaning process are
classified into two:

I. crop factors that include crop variety, maturity stage, grain moisture content, straw
moisture content, bulk density of crop, bulk density of straw, stalk length, terminal velocities of
particles (both grain and other materials), grain size and

18
II. Machine factors such as frequency of sieve oscillations, amplitude of oscillation, slope,
length, width and sieve whole diameter and fan speed. Teff crop has high biomass such as chaff,
dust and broken straw during threshing that makes it difficult to separate grain from foreign
materials by using solely one separator.

3.1.4 Blower

Aerodynamic separator and cleaner use air as a medium to lift light materials such as chaff and
dust out of mixture of grain and undesirable materials; i.e. heavier materials moving downward
while light materials are blown away.

The blower was designed to stream artificial air horizontally to blow out mixed product injected
along the vertical plane. The blower was made up of 1.5mm sheet metal, 30mmx6mm flat iron,
25mm diameter mild steel shaft,4mmx40mmx40mm angle iron, 1mm sheet metal to house the
fan(blower), eccentric pulley to create oscillation motion and bearing with housing.

Figure 10 Blower

The choice of fan type for a given application depends on the magnitudes of required air flow. For
a given fan type, the selection of the appropriate impeller depends on rotational speed. Speed of
operation varies with the application. For agricultural applications, fan speeds are recommended

19
to be between 450 and 1000 rpm. Indicated that the initial data required for the design of a fan are
the mean velocity of air stream flow at its exit (clean), the volume flow rate (V). The flow rate of
desired air stream is determined form the concentration of the material entrained by the air, µ given
as ratio of Gm to Ga and has a value between or equal to 0.20 and 0.30. The volume flow rate of
air required making separation between grains and MOG can be estimated from the equation given
below.

= =
( )

Where: V = volume flow rate (m3/s),

= the mass flow rate of air (kg/s)

= the quantity of material removed by the air stream per unit time

µ = coefficient of concentration (unit less),

ρ = density of air (kg/m3).

The dynamic head

ℎ =
2

3.1.5 Sieves

In mechanical separation mixed materials are moved over a perforated and oscillating surface with
openings of specified shape and size. Mechanical or sieve separation is a process separating the
desired material/grain from undesired materials depending on their size and shapes. In this way
three step sieves made from 1.5mm sheet metal, 1.5mm square pipe, 3mm, 2mm and 1.5mm hole
diameter perforated sheet metal of 1.5mm thickness was included in the machine. The length of
the sieve was made 1.2m to manage the size of the machine and the slope of the sieve is adjusted
by moving the front sieve support up and down.

20
 Figure 11Sieves and its compartment

3.1.6 Frame

The frame of the thresher will made up of 4mmx40mmx40mm angle iron and 1.5mm sheet metal.
The frame also has the concave seat and concave cover on sides as well as the frame was made at
angle to decrease the vibration.

Figure 12 Frame and engine seat

3.1.7 Shaft

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

21
causes the shaft to bending. In other words, we may say that a shaft is used for the transmission of
torque and bending moment. The various members are mounted on the shaft by means of keys or
splines.

The following factors were considered in the shaft design;

1. It must be rigid enough to withstand the twisting and bending moment

2. The shaft should be durable and tough

3. The shaft must be wearing resistance and strong enough to with stand all the shock loads
during service.

The design of shaft includes the determination of the correct shaft diameter to ensure satisfactory
strength and rigidity while transmitting power under various operating and loading conditions.
Design of shaft is based on the maximum shear stress theory. Shafts are usually subjected to
torsion, bending, and axial loads. For a solid shaft having little or no axial loading, the diameter of
the shaft can be calculated using the equation given by ASME code as:

d3= 16 √(( )2 + ( )2)/

Where:

d = diameter of the shaft (m), Mt = torsional moment (Nm), Mb = bending moment (Nm),

Kb and Kt = combined shock and fatigue factor applied to bending and torsional moment
respectively. Kb = 1.2 to 2.0; Kt = 1.0 to 1.5.

max = allowable stress (55 MPa for shaft without key way and 40 MPa for shaft with for rotating
shafts, when load is suddenly applied (minor shock): It must be noted that factor of safety needs
to be considered in actual design work.

Torsional moment (Mt) can be calculated as;

22
 ( − )
=
2

Where:

Ti = tension on tight side of a belt (N) Tj = tension on slack side of a belt (N),

D2 is the diameter of driven pulley (mm).

To determine tensions on the tight and slack sides of a belt the following equations can be used.

Figure 13 Threshing holding shaft

In this design the machine comprises of two shafts. From these one is to be fitted to the threshing
drum and pulley. The other shaft is used to fan system.

3.2 Machine description

 the machine consists of the following  V-belts
components:  Bearings
 Left and right support and cover  Front and side cover
 Fan blower  Inlet hopper
 Shaft Pulleys  Lead screw
 Discharge  Exhaust chat straw and cobs
 Bolt and nut
23
  Cart wheel  Key and key sets

The shaft carrying the spikes is suspended on two ball bearings. The spikes are arranged with a
uniform pitch. The bearings carrying the shaft are mounted on the structural frame work. The
barrel cover carrying the inlet hopper houses the de- cobbing cylinder. The throat of the inlet
hopper fits into a square hole created at one end of the de- cobbing cylinder. Both the barrel cover
and the de- cobbing barrel are static. The barrel is split in to two halves but held at one side with
hinges so that it can be opened and closed. The electric motor or engine is mounted at one lower
end of the structural frame. The assembled blower is mounted to the side of electric motor. The air
exit channel of the blower is connected against the cereal crops exit spout. V-belts are used to
connect the shaft carrying the beaters, the blower shaft to electric motor shaft via pulleys. All the
components of the machine are mounted on the rigid structural support and cover. The assembled
machine has the following dimensions: Overall length 1.40m, width= 0 .95m, height 1.4m,
Diameter and length of cylinder drum 0.40m and 800mm respectively.

3.2. Material review

It is necessary to evaluate the particular type of forces imposed on components with a view to

determining the exact mechanical properties and necessary material for each equipment.

Materials review

Stainless Steel

This is a widely used material for engineering purposes. This stainless-steel type is easy to machine
with good weld ability and easy to form. It has a tensile strength of about 520- 720MPa.

Advantages

 It has excellent corrosion resistant

 It remains ductile to the lowest temperature
 Stainless steel 304 does not wear easily
 It has excellent durability in acidic environment
 In fuel, oil solvent, stainless steel 304 maintain excellent durability.
 Easily available to purchase.
24
  It is environmentally friendly.

Disadvantages

 This type of stainless steel rapidly work hardens.

 It is a little expensive.

Mild Steel

Mild steel contains approximately 0.005-0.25% carbon making it malleable and ductile. It has a
relatively low tensile strength, but it is cheap and easy to form; it is often used when large quantities
of steel are needed. Mild steel contains less steel carbon than other steels and are easier to cold-
form, making them easier to handle. Below are some properties of mild steel which makes them
excellent choices for thresher fabrication.

Properties of Mild steel

Weld ability:

Weld ability is defined as “the capacity of a material to be welded under the imposed fabrication
conditions into a specific, suitably designed structure and to perform satisfactorily in the intended
service”. Carbon steel is generally considered to be quite weldable, particularly when the carbon
content is below 0.35%. The term weldability is also used in a narrower sense to mean the ease
with which a material can be welded without cracking or other discontinuities. Mild steels and
rarely present problems, as long as impurity levels are kept low. Mild steel is all wieldable without
preheat, using any of the common welding processes.

Forming or Forging:

Forming operations on carbon steels include any method of plastically deforming the material to
achieve the desired component. Included are bending (both hot and cold), rolling, extrusion,
drawing, and forging. Carbon steels are capable of being formed extensively due to the relatively
high ductility of the material. Forming that is performed at temperatures lower than the
transformation temperatures will result in cold strain, which can both increase the strength and
reduce the ductility of the component. Mild steel can be formed into different shapes and forms.

Machinability:

Machinability can simply be defined as the ease with which a material can be machined.
Machinability can be based on tool life, cutting speed, power consumption, comparison with
standard steels, quality of surface finish, and feeds resulting from constant thrust force. As with
other properties such as strength, hardness, and ductility carbon content is the dominant factor in
25
machinability. Mild steels can easily be machined with the right tools whether the shaft or metal
sheet.

Cast Iron

Cast iron is a group of iron-carbon alloys with carbon content greater than 2%. The alloy
constituents affect its color when fractured. Cast iron is a metal which is recommended for very
few components of the thresher.

Property of Cast Iron:

 Good compressive strength

 High damping capability (tool machines)
 Good machinability
 Good wear resistance (graphite as lubricant)

3.3. DETAIL DESIGN ANALYSIS

The design analysis was carried out with a view to evaluate the necessary design parameters,
strength and size of materials for consideration in the selection of the various machine parts in
order to avoid failure by excessive yielding and fatigue during the required working life of the
machine.

Design specification

Drum diameter = 400mm

Drum type: Peg tooth with an open threshing drum

Drum shape: cylindrical

Cleaning mechanism: using blower and sieve

Source of power: A Diesel Engine

Type of drive: v belt drive.

Over all height of machine =150cm; here minimum height of man was taken in consideration.
Maximum length of machine=120cm.
26
Total length of shaft=100cm.

Length of threshing drum=80cm; we consider the maximum height of teff plant which is 80cm.
The density of teff at different moisture content (%, wb) from 11.94 – 27.10 be 1361.82kg/m3 –
1252.91kg/m3.

Direction of shaft rotation should counter clock wise according to the industrial standard of metric
system.

Grain size and morphology of Teff

Thousand teff grain weight (TGM) be from 0.2920gr – 0.4207gr.

Teff grain length= 0.9 to 1.7mm,

Grain width = 0.7 to 1.0mm.

Concave hole and clearance between one beater and concave bar=5mm.

The sieve opening is needed to be equal with the average value length of teff grain Clearance
=((1.7+0.9))/2 mm, =1.3mm and concave hole=5mm.

3.3.1 Design of Drum

Material: Mild steel

This component is responsible to cut and separate crops due to the direction of the threshing shaft
mounted on it held between concave and drum.

Once a teff crop manually fed in to the hopper is threshed by this mechanism both separated parts
or grain and straw pass through the clearance gates holes and fall to the sieve. The principle
parameters of threshing are the drum length, diameter and number of teeth or beater, feed rate and
required power will be determined.

To determine the feed rate (q) of the thresher on the basis of grain output and grain straw ratio (δ):

Using the relationship

δ=

Where, δ = Grain to straw ratio

27
 =output straw

= grain output

Let us calculate the feed rate for an output of 600Kg/hr. or 6quntal/hr. grain having straw grain
ratio of 1.3.

Output straw (qs):

=1.3

= ×1.3= 600×1.3kg/hr=780kg/hr So total feed rate will be:

qs+qg= 600+780 (kg/hr)

=1380kg/hr.=23kg/min

= 1380kg/3600sec

= 0.383kg/sec

Revolution of thresher (N)

The revolution of thresher per second is given by: -

ℎ ( )
=
πD

Where, D = diameter of cylinder in ‘m’

Let peripheral speed of cylinder for teff crop be 15.69m/s.

Let diameter of cylinder be 40cm.

.
= =12.49re/sec.
πx0.4

= 12.50rev/sec (say)

= 750rpm

Number of pegs (beaters) in the peg/spike tooth type power thresher is given by: -

= ( + 1)
28
Where, Nb= Number of pegs or beaters

P = number of pitches of helix over which beaters are located

ld = length of drum (assume 800mm)

a = constant assume 50mm Also,

p=Cb/2 Cb = Number of cross bar (assume Cb= 8) Thus, p = 8/2= 4

Therefore, = 4( +1) = 64beaters

And another accessory of drum is scooper with the following dimensions: Length, L =
150mm

Height, H = 70mm

Assume the beater has a dimension of Height, (H) = 65mm, Diameter, (D) = 10mm.

The clearance between the Consecutive beaters (Cb) will be:

ℎ − ℎ
=
.

800 − 150
= = 81
8

So; X=81mm is proportional with the length of the drum.

Calculation of power requirement for thresher: -

Power requirement for thresher is given by: -

( )
= mv2 +nv3

Where, p = power required for operation of thresher, in watt q = feed rate, kg/sec

v1=initial velocity of plant, 3m/s

v2 = velocity of plant mass after impact

V = peripheral Velocity of threshing drum, 15.69m/s

29
 = coefficient of friction between straw and thresher 0.6 (assumed)

m = a constant 5 – 5.5 N per 100 kg weight of threshing drum

n = a constant 0.045 N – sec2 /m2 length of 550mm drum Velocity of plant mass after impact
(v2) in thresher is given by: - V2 = α× v

Where, α = 0.7 to 0.85

V = peripheral Velocity of threshing drum, = 15.69m/s.

Therefore, V2 = 0.75×15.69m/s

= 11.7675m/sec

Putting the value in the above formula: -

(11.7675 − 3)
P = 0.4kg/sec / × 15.69 / + 5.5 × 15.69 / + 0.045
1 − 0.6
70
− / × × 0.8 × (15.69 / )
55
. × . × . × .
= 86.295 + 257.76 ( 9.81 )
.

= 36234Watt P = 3.6234Kw

Considering Transmission losses and Extra starting power and also power for sieve
oscillation and blower 6kw Engine is recommended.

Angular velocity of cylinder is calculated as: -

×
=

Where, V = linear speed of drum (shaft)

Dd=diameter of the drum

ω = angular velocity of the drum (shaft) in rad/s,

N = Rotational speed of Drum or shaft in rpm = 750rpm

× ×
= = =78.54rad/s

30
Now, the total torque required is given by:

p= ×ω where: p= total threshing power

Tt = = 46.134 =

Assume the numbers of tongs on one of the beater metals to be 8. total 8 flat metals are

required. Kt=8*8=64

Tt=Tr*k Tr=Tt/k=46. 134N.m/64=720.8N.mm

I. bending stress σb= M/z= 4M/(π*t* )

Where σb= bending stress

M= bending moment, Z= section modulus The

maximum bending moment M is given by:

M= q.L/2

Where q= distributed force. L = length of tong. q= on each tong is equal to the force and is
given by:

q=1.03N Now, M= q.L/2 where L= 60mm

M=1.03N*60mm=0.0309mpa

Assuming weld thickness t=3mm and diameter d=15mm beater

∗ .
σb= M/z= 4M/(π*t* )= ∗( . ) ∗ .
=0.0583Mpa

II. shearing stress the shear

stress τs is given by: τs= F/A

Where F= applied force

A = throat area and is given by: A= π *d*t= 0.7071*π*d*x

Where d= diameter of tong

31
X= size of weld

The section modulus Z= π*t*d2/4=0.07071* π*d2*X/4 substituting the corresponding

values and we get

t= 0.7071*x where t= 3mm

x= 3/0.7071=4.24 mm

Say x= 5mm

Now, A= π*d*t=π*0.015*0.003 = 141.372*10-6mm2 and F=1.03N

Now, τs=F/A Substituting the values and we get, τs=0.0073Mpa

based on the maximum shear stress theory

τsmax= ½ (√ (σb2+4 τs2)) Substituting the given values and we get:

τsmax= 0.03Mpa

Figure 14 Drum beater

3.3.2 Design of concave

Material: mild steel.

32
The concave is stationary part that the cylinder or drum works threshing action on it. The
concave should great compose of rod and brass. “Increase concave clearance results in
increase threshing efficiency and capacity while increase concave clearance increases
threshing loss. Decrease concave clearance may have increase chance of grain to be stacked
between teeth s and Increases feed rate, threshing efficiency decreases while threshing loss
increase”.

It is a curved piece that have a concave bar which are perpendicular to the flow of crop. The
material it is Mild steel sheet metal.

The effective arc portion is responsible to thresh and that is why we called it concave.

We have effective length of concave (L)

Concave radius (r) = cylinder radius of pitch tooth radius. Now area of concave portion or
peripheral is, A is given by A=2π×r×L, for full circular object peripheral area, but A=π×r×L
(half curved object at shown below)

= π×282.5mm ×800mm= 709640 2 = 0.71 2

From the geometric analysis, number of rows to be girded was 40 rows and 40 for rod bar
number, Plate 40×4mm.

Figure 15 Concave

33
 3.3.3 Design of Cylinder cover

Material selected: Mild steel (sheet metal)

Dimensions:

Diameter of upper drum covers (Duc)

Duc= diameter of drum + beater height + clearance between drum beater and upper cover

= 400mm + 2×65mm + 2×5 mm = 540mm,

Length (l) of drum = length of drum =800mm,

Thickness (t) =2mm.

Figure 16 Cover plate

3.3.4 Selection of belt

We select a V-belt drive, because of the following reasons:

 Center to center distance is small.

 Very strong
 Give compactness due to the small center distance of the pulleys.
 The drive is positive b/c the slip b/n the belt and the pulley groove is negligible. It
provides longer life, 3 to 5 years.
 It can be easily installed and removed.

34
  Since the V- belt is made of endless and there is no joint trouble, the drive is smooth.
The operation of the belt and pulley is quiet.

Characteristics of V- Belt drive:

 Initial cost- cheaper

 Maintenance- low
 Lubrication - none
 Shock absorption- better
 Life- longer
 Noise- low
 Efficiency = 87-97%.

Agricultural V- Belts:

Agricultural V-belts require intermittent shock loads and ability to bend in reverse over
small diameter sheaves. As a result, agricultural belts incorporate an under cord which acts
to prevent the belt from wedging in to the sheave when subjected to shock loads and a
flexible jacket. Double v belts are intended for such drives.

Generally, it is recommended that belt speeds in the range of 20m/s (4000ft/min) be used
where feasible 15-20 m/s for efficiency and longer life. The power transmitted by a belt
depends up on

1. Difference in belt tensions

2. Co-efficient of friction
3. Area of contact
4. Center distance

Table 6 Belt Material

Rubber Dry Wet Greasy

Coefficient of 0.3 0.16 0

Friction

35
 Figure 17 Belt tensions[21]

Let: D1= diameter of smaller pulley D2= diameter of larger pulley

N1= rpm of smaller pulley N2= rpm of larger pulley

V1 =speed of engine (smaller) pulley V2=speed of larger pulley

Based on the specification, let the engine rpm, N1=3000rpm Drum rpm, N2=750rpm

Now from relation we have the following:

1 2
=
2 1

Now, substituting the above values and we get:

2
2 = 60 ×
2

But v2=linear speed of drum=15.708m/s

So,
15.708 /
2 = 60 × = 400
750

1 2 2
= → 1= 2× = 100
2 1 1

The peripheral speed of the belt is given by

36
 1
1= 1×
60

Substituting the above values and we get:

V belt= V1

1= × 100 × =15.7m/s≅16m/s (speed of smaller pulley).

Power of belt drive:

Power (Pb) of belt drives is given by:

Pb=power transmitted ×safety factor (FS).

For uniform driven machinery, safety factor (FS) = 1-1.2 (Say FS =1.15) Now; Pb = 6Kw×1.15
= 6.9Kw

Torque transmitted by the belt:

P=T×ω

Where; ω (angular speed) = 2 ×

T=torque P = power

60
= = 56.6
2 × 1

Using this torque, the corresponding type of belt and pulley diameter is:

V Belt Designation

Type of V belt Torque transmitted (Nm) Min diameter (mm)

(designation)

B 50-150 125-200

Center to center distance:

Center to center distance is calculated by: C= (0.07-0.1) ×v belt.

Take 0.08 to be the multiplication factor.

37
C=0.72m

Angle of contact on pulleys

1. The angle of contact on smaller pulley is given by:

θ1=180-α

−1
θ1=180-2 degrees

θ1=176.20

2. The angle of contact on the larger pulley is also given as :

θ2=180+2α

−1
θ2=180+2 degrees

θ2=183.80

3. Length of the v-belt:

( 2 + 1) ( 2 − 1)2
= + 2 +
2 4

Then substituting the values gives; L= 1.97m

38
 Figure 18 V belt sections B type

From table for v belt sections B type

b=17mm and, where: b= width of the belt, t= thickness of the belt t= 11mm

Belt is made of rubber with a density (ρ) =1000kg/m3

4. The power transmitted by the belt is given by:

P= (t1-t2) ×V Where, t1= tension on the tight side (N) t2= tension on the slack side (N)

V= velocity of the belt in m/s

Now, t1 can be found from t1=T1-Tc

Where Tc is the centrifugal tension of the belt, and it is calculated by: Tc= m×v2

Where, m= mass of the belt per length

And the mass m is given by:

m=area (A) ×length (L) ×density (ρ)

Where; A=b*t=17×11=187mm2=1.87×10-4m2

m=1.87×10-4m2×2m×1000kg/m3=0.374kg Tc=0.374kg ×(16m/s)2=95.744N

We know that the relation between t1 and t2 is given by:

2.3log (t1/t2) =µ θ cosecβ

And, Take µ of rubber = 0.3

39
At θ =176.20=3.07 radians and let angle of groove β=200

2.3log (t1/t2) =0.3× 3.07 × cosec200

Log (t1/t2) =0.426

1/ 2= 2.7… (By taking antilog)

The maximum tension in the belt is given by:

T=σ×b×t

Where σ=allowable bending stress

B= width of the belt t= thickness of the belt

For rubber B belt type: σ=2.1Mpa, b=17mm, t=11mm T=2.1×106×0.017×0.011

T = 392.7N

Therefore, tension in the tight side of the belt can be obtained from T1= T-Tc

T1= 392.7N-95.744N T1 = 296.9N

Now from (1) we get:

T1/T2=2.7

T2=110N

Now, the power transmitted by the belt tensions is given by: Pt= (t1-t2) ×v

Pt = (296.9N-110N) ×16

Pt = 2990.4

Pt= 2.99kw

Figure 19 V belt and pulley

40
Selection of Pulley

Figure 20 Pulley dimensions

Material selected, cast iron

Reason why:

 Very strong, good machine ability.

 Economical.
 Stable
 Excellent frictional characteristics.

1. Stress analysis of pulley

σt= ρ×v2 Where;

σt=Centrifugal stress induced in the run of pulleys,

ρ = Density of the rim material= 7200 kg/m3(for cast iron)

ν = Velocity of the rim =πDN/ 60, D being the diameter of pulley and N is speed of the pulley.
Now, V1= speed of smaller pulley

V1= π×D1×N1/60= π×0.1×3000/60

V1=15.7m/s

Similarly; V2 can be calculated and has a value of

41
V2= π×D2× N2/60

V2= 15.7m/s.

The centrifugal tensions of the belts respectively are given: σt= ρ×v2= 7200×
(15.7m/s)2=1.775MPa

2. Dimensions of arms Tangential load per arm,

2
= =
2

Where; t= torque transmitted r= radius of pulley

n= number of arms.

From standard for pulleys diameters ranging from 200-600m; n=4 We know that the torque
transmitted is given by:

T= 60 Pt

2× π× n2

Substituting the corresponding values and we get

T= 714.17N.m

2
=
×

= 560.9N

Cross section of arms is given by:

M/Z =σb where M= maximum bending moment on the arm at hub end.

Z = section modulus of arm, Z= π×d3/32

σb = bending stress for arm material.
2 2
= =

42
 2 714.14
= = 357.07
4

The allowable bending stress for cast iron pulleys is given as: σb (all) = 15Mpa. Then from the
relation

= ( )

= = 357.07 × 103
( )

Z= 4676mm3

Again, Z is given by: = × from this equation we can get

3 = 32 × , putting the above values and we get

d= 36.24mm

Say d= 38mm (to make standard)

Determination of hub diameter d1=2×d

Where d= diameter of shaft=25mm d1=diameter of hub

d1=50mm

The minimum length of the hub is given as: = ,or =

Where B= width of pulley and it can be obtained as: B= b+13 [7](table 19-2; page 719)

B= 4×17+13=81 mm

Now = 2×

= 54mm

Say L= 60mm

Small pulley analysis

43
Material: cast iron

The centrifugal stress induced in the rim of pulleys, σc= ρ×v2

Where ρ = density of the rim material

ρ = 7200kg/m2 (for CI)

v = velocity of rim and is given by:

1 11.78
= × 1× =
60

Now substituting these values, we get,

σc = 1.02Mpa.

Arm considerations:

Tangential load per arm:

= ×
2

Where T= torque transmitted by smaller pulley.

= 60 × = 121.53 .
2× × 1

= 2× = 303.83
×

Cross section of arms

.
Where = and = 2× =2× = 60.765

σb= 15Mpa

Now, = 60.765 × = 4051 3

44
Again, Z can be given by: = ×

Equating these equations, the value of d will be:

d=35mm

Determination of hub diameter

From the measured data of motor shaft diameter d= 25mm (as we calculate below) Since shaft
diameter d = 25mm

Now hub diameter d1= 2×d= 50mm

3.3.5 Design of Shaft

A shaft is a rotating machine element which is used to transmit power from one place to another.

These shafts which supports the threshing drum and transmit power to it is a back bone having
multiple purpose. It also transmits power to the clearance system that is to the fan and cylinder
through belt and to the sieve. So, to select proper material for this component ought to consider
the following properties:

 Should have good machine-ability

 High strength
 Good wear resistance
 Low notch sensitivity factor

This shaft is subjected to bending stress due to the drum load and the tension or reaction at both
ends, further it is subjected to shear due to the transmission of torque or torsion load. The load of

the shaft itself is also taken in consideration for the bending stress evaluation .so that shaft is
subjected to combined twisting and bending load.

To select the shaft in addition to the above consideration shaft availability, material type

, suitability for working condition and cost of material should also consider so from the following
table the material used for shaft is steel (40c8) with the following mechanical properties.

 Ultimate tensile strength, σu= 560-670Mpa.

 Yield strength 320 Mpa which satisfy the above properties and it is recommended.

45
 Table 7 Mechanical properties of steel shaft

Indian standard Ultimate tensile strength, Yield strength, Mpa

destination Mpa

40c8 560-670 320

45c8 610-700 350

50c4 640-760 370

50c12 700MIN 390

Now to calculate the diameter of the shaft the following parameters and calculated values are set
first.

Length of shaft, L=1000mm (from geometry) Power=6Kw at 750rpm

.
So torque, = where = 2 = .speed in rpm

ω = angular speed and P=power

6000
= = 76.3 = 76300
78.5

Assuming that the load due to the weight of the shaft itself (w1=40N), due to the threshing drum
(w2=200N), crop material (w3 = 0.3N) and weight of shaft (37.77N) which is uniformly
distributed, Placing pulley weight at the end of the shaft (w=8N) for 100mm diameter. Tension of
the belt on the pulley on the left side,

T1=296.9N and T2=110N.

The pulley weight =8N.

Now the forces acting on the shaft can be determined as follows: F1=w1+w2+w3+w4

= 40N+200N+0.3N +3.85N

=240.3N F2=T1+T2+w

= 296.9N+110N+8N

= 414.9N
46
Where F1= total load acting at the Centre.

F2, total force act at right side of the shaft due to the tension of the belts. Now the shaft diameter
can be calculating according to the theory of maximum shear stress.

16
3 = × ( × ) + ( × )

Where d=shaft diameter

s =allowable shear stress of the shaft

Kb =shock factor for the bending moment=2 for rotating shaft. Kt=shock factor for torsion moment
=1.5

= Maximum bending moment (Nm) Mt =maximum torque (Nm)

Now the allowable shear stress s=1.8 or 0.3 based on ASME code for shaft.

s= ×0.3=0.3×320Mpa=96Mpa.

For rotating shafts suddenly applied loads with minor shocks only the correcting factors will be

Table 8 Correcting Factor

Nature of loads Kb Kt

1. Stationary shafts

(a) Gradually applied load 1.0

(b) Suddenly applied load 1.5

–
2. Rotating shafts
2.0
(a) Gradually applied or steady load

47
 (b) Suddenly applied load with 1.5
minor shocks only

1.5
–
2.0

(c) Suddenly applied load with 2.0

heavy shocks –
3.0

Let’s calculate the Mb and Mt be for this reaction forces RA and RC and then the horizontal and
vertical bending moment should calculate.

Let’s take summation of moment at the reaction is zero and solve reaction as follows:

In order to calculate reaction forces RA and RC, it was considered that:

∑ =0

= × 800 – 1 × 400 − 2 × 1000 = 0

. × . ×
= = 638.775 upward.

RC = 638.775

∑ =0
48
= RA + RC – F1 – F2 = 0 RA = 240.3 + 414.9 – 638.775

= 16.425N RA = 16.425N

B.M (bending moment) from the left side over hang pulley from the nearest bearing is calculated
as follow:

B.M at B = 16.425N×0.4m + 638.775N × 0.4 − 414.9 × 1

=-152.82Nm or152, 820Nmm

B.M at C = 240.3N× 0.4 − 414.9 × 0.2 − 16.425 × 0.8

= 0 Nm

B.M. between point C and D (i.e. point O)

∑ =0

= −16.42N × 900mm + 414.9N × 500mm − 638.775N × 100mm

= 128794.5Nmm = 128.7945Nm

So, bending moment at B is maximum B.M therefore Mb=152820Nmm and we have, Mt, the
twisting moment due to the torque was calculated above and T =Mt=76300Nmm. Hence the
equivalent twisting moment, Te will be,

= ( × ) + ( × )

= (2 × 152820) + (1.5 × 76300)

Te = 118742.97Nmm

From the last equation above, we get

49
 √
= 16
×

16
=
×

= 6302.705 3

= 6302.705 = 18.47

We now also the equivalent bending moment (Me)

According to maximum normal stress theory, equivalent bending moment:

1
= [ × + ( × ) + ( × ) ]
2

= Kb× +Te

= 0.5× 152820 + 118742.97Nmm

= 195152.97Nmm

We also know that the equivalent bending moment (Me),

= × ………… (Take b = 100 = t, )

3/ = 32 × = 32 × 195152.97/ × 100 = 19888.20 3

= √19888.20 = 23.76

= 23.76

We take the larger of the two values, we have D = 23.76mm say to next standard 25mm

50
Figure 21 Bending moment diagram

Torsional rigidity

The, or angle of twist has great role to distinguish the safety of the shaft torsion rigidity is very
crucial in case of cam shaft when timing would be affected. The permissible amount should not
excess, 0.25 per meter length of such shaft.

This may obtain by using the torsion equation so,

×
= , =
×

51
Where, =torsional deflection, or angle of twist in radians T =twisting moment or torque of the
shaft =76.3Nm.

Ј=polar moment of inertia for cross sectional area about the axis of rotation
4
= × /32

G=modules of rigidity or the shaft materials.

L=length of the shaft =1m

G=77.2× 109 N/m2 for stainless steel

× (0.025)
= = 3.8 × 10
32

76.3 ×1
= = 0.026
77.2 × 109 / × 3.8 × 10

= 0.026 × = 0.135

= 0.135

= 0.026rad

The angular twisting between the bearings is less than 0.25 ,So that the shaft based on the torsion
rigidity is safe

Weight W, of the threshing shaft is given by, W=A×L×ρ×g

Where, A =cross sectional area of shaft, L= length of shaft,

ρ=density of steel or shaft material=7850kg/m3,

W= 2/4×L×ρ×g =π/4×252×10−6×7850×9.81=37.8N

Mass, M=W/g=37.8/9.81=3.85kg

Figure 22 shaft with dimension

52
 3.3.6 Design of keys

We select rectangular sunk keys type, are provided half in the keyway of the shaft and half in the
keyway of the hub or boss of the pulley. The material we select is mild steel

σ=560-670Mpa

τ= 320Mpa

FS=3, with τall=106.7Mpa σall= 200Mpa

I. Design of key for larger pulley

From table at shaft diameter, d=25mm the corresponding width and thickness of the key are:
w=10mm, t= 8mm

Now the length of the key is obtained by considering the key in shearing and crushing. Considering
shearing of the key (or torque transmitted) of the key.

= × × ×
2

25
= × 10 × 106.7 × = 13337.5
2

Where, = 60 ×

= 60 × , since P=6Kw and N=750rpm

×

=764.33Nm

Now equating: T=13337.5L 764.33Nm=13337.5L

L= 17.45mm

Remark: The length of the key should be at least equal to hub length. Since the hub length is taken
as L=30mm

Now the length of the key should be Lk=30mm

Checking the key for shearing and crushing:

53
 Figure 23 key dimension

Let’s now check the induced shear and crushing stresses in the key.

Figure 24 Key

Shearing:

= where: F= force applied ds= 25mm

As= shear area T= 121.59Nm

F= T/r= 9727.2N r=ds/2 = 25/2= 12.5mm as= l×w= 600×106

τs= 16.212Mpa.

Since this is less than (16.212Mpa<50Mpa). Therefore, it is safe. Crushing:

σc= F/Ac where Ac= crushing area= × = 30 ×

F=9272.2N

Now, σc= 38.63Mpa

54
Since this is less than (38.63<80). Therefore, design of the key for crushing is safe.

3.3.7 Selection of sieves

Perforated plate sieves can be supplied in frame materials of brass or stainless steel and are all
manufactured to the highest engineering standards to ensure quality and accuracy and this type of
sieves are selected for this project.

By taking the dimension of teff, sieves can be selected from the above standard table.

Length and equivalent sphere diameter of teff increased from0.9 to 1.7mm and 0.71 to 0.87mm
respectively. Then from the table above: -

 Sheet quality – Stainless steel1.430

 Perforation – round
 Hole – 3 mm,2mm and 1.5mmFor three successive layer of sieves
 Pitch – 5 mm,3.5 mm and 2.6mm
 Thickness – 1 mm
 Length – 900mm
 Width – 800mm

Figure 25 Sieve
3.3.8 Design of fan (Blower)

A centrifugal fan was constructed from a sheet metal of 1.50 mm thickness. It was mounted on a
shaft with a diameter of 25 mm and supported on roller bearings. The fan assembly had four radial
blades. The fan blades were 38 cm in length and 8cm in width. The fan was operated at three
different angular velocities where the maximum being 1000 rpm. The fan speeds were adjusted

55
and set at desired level by adjusting engine speed and employing pulleys diameters rather than
gears.

The air entrance into the fan housing was at 90 to the air outlet opening. The air enters the fan
housing parallel to the fan shaft and then rotated through 90 by the fan blade before discharged.
The fan discharged air with constant velocity of 3.2 m/s (the minimum terminal velocity of teff)
through the exit. This constant air speed was adjusted using a digital anemometer and either by
decreasing or increasing the air inlet openings on the sides of the fan housing. The inlet openings
could be closed and opened using the shutters provided to maintain the desired air velocity.

The factors considered in the design were, quantity of air to be moved per unit time, amount of
noise permitted and economic factor.

The terminal velocities of the grain were obtained using the relationship;

=1.74( ( − )1/2 /

Where, = terminal velocity (m/s).

g = acceleration due to gravity (9.81kgm/ 2)

= Particle diameter (0.86mm)

3
= particle density (1314.85kg/ )
3
= air density (1.2kg/ )

So, = (1.74(9.81×8.6×10−4(1314.85−1.2)) ½)/1314.85 = 3.2m/s.

The volume flow rate of air (V) at fan exit was calculated to be 0.077 m3/s (velocity of exit (3.2
m/s) x cross sectional area at exit (0.024 m2) = 0.077 m3/s). Using the equation given below,
quantity of material removed ( ) by the air stream per unit time (kg/s) was determined to be
0.023kg/s.

= =

Where

V = volume air flow m3/s,

γ = density of air (1.2 kg/m3)

56
 = the mass flow rate of air at exit which equals to the flow rate fan exit multiplied by the density
of air (V×γ = 0.077 x 1.2 = 0.092 kg/s), and

= a coefficient 0.25.

The dynamic head (ℎ ) of the fan was calculated using the equation given below and assuming

= terminal velocity of teff grain = 3.20 m/s and density of air 1.2 kg/m3 was found to be 6.14
Pa.

ℎ =
2

The inlet area ( ), coefficient (k), static head (ℎ ) and overall pressure head (H) were computed
for different fan rpm and given in Table below

Table 9 Adjusted inlet area at different rpm to keep constant 3.2m/s at fan exit
2
Fan speed Inlet Area K= ℎ =
(1− ) ℎ Vt(m/s) (anemometer Over all pressure
2
(rpm) reading at fan exit) head
(pa)
(cm2) (H = hs +hd)

500 210 0.88 1.79 3.2 7.93

740 200 0.83 2.77 3.2 8.91

1000 160 0.67 7.54 3.2 13.68

57
 Figure 26 Blower

3.3.9 Bearing selection

A bearing is a machine element which supports another moving machine element. 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. 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)

We select rolling bearing due to contact between the surfaces in rolling.

58
 Figure 27 Standard designations of ball bearings[17]

From roller bearing we select ball bearing because it has high load carrying capacity; by using
shaft we select bearing number ‘305’ because of the following reasons:

1. The medium (300) series has a capacity 30 to 40 per cent over the light series.

1. 05×5=25mm, shaft/bore diameter

Table 10 Principal dimensions for radial ball bearing.

Bore (mm) Outside Width

diameter(mm) (mm)
Bearing No.

205 52 15

305 25 62 17

405 80 21

And we read above table: Do=62 and w=17mm

Now the Dynamic load rating (L)= ( / ) × 106 revolution

/
Where, C = Basic dynamic load ratting=

59
L = Rating life,

W = Equivalent dynamic load, and k = 3, for ball bearings,

Assume we select row deep groove bearing working for an average life of 5 years to 8 hours per
day, uniform, steady load condition and 300 work days.

So, life of bearing, LH=5 × 300 × 8=12,000hours

L=60 ×N ×LH= 60 × 60 × 12,000 =43.2 ×106revolution.

Figure 28 Bearing dimension

3.3.10 Design of blower cover

Material selected: Mild steel (sheet metal)

2
With over all dimensions D = 300mm, L= 450mm, t=1.5mm. Area of air inlet = 314

60
 Figure 29 Blower cover

3.3.11 Design of support frame (stand)

Material selected: Mild steel with σu= 540Mpa and τu= 540Mpa

We select that 4mmx40mmangle iron, 1.5mm sheet metal, 4mmx40mm square pipe, and 16mm
diameter normal round bar to support the sieving part. The frame also has the concave seat and
concave cover on sides as well as the frame was made at angle to decrease the vibration.

Now Consider the support as column with one end free and the other end fixed the critical load
(crippling) load is given by:

ℎ
=
1+

×
=
1+

Where σc= crushing or yield stress in compression

a= Rankin constant= σc/(π2 × E)

L= equivalent length of the column and

K=least radius of gyration =

61
Table 11 Relation between equivalent Length (L) and actual length (l)

S.no. End conditions Relation between

equivalent length(L)
and actual length(l)

1 Both ends hinged L=l

2 Both ends fixed L=

2

3 One end fixed the other hinged L=

√2

4 One end fixed and the other free L=2l

Table relation between equivalent length and actual length

Assume one end free and the other end fixed:

So, L=2l

Cases for buckling to occur:

1. If Wcr<Wappor where: Wcr= Crippling load by Rankine’s formula,

2. σ>σallWapp=weight applied on the support frame

The weight applied on the support frame; assume it is the weight of the beater, pulley, cover, shaft,
and weight of bearings plus bolts and spikes to be:

W=Wbr+WP+WC+Ws+Wb+Wsp

Where; Wbr=19N, WP=623N, WC=43.7N, Ws=37.8×2+20=95.6N, Wb=6N, Wsp=16N

Now the total weight

WT= 19N+623N+43.7N+95.6N+6N+16N=803.3.

Since we are considering the frame as a column:

The force applied on one of the supports with angle 150, we take this angle in order to decrease
vibration is given by:
62
 cos 15
= 194
4

Factor of safety for steady loads is given as: F. S= (5-6), (F. S=5.5)

Therefore; the critical load

Wcr=5.5×194N= 1066.9N

Assume the support is angular iron type steel with dimensions of b=t =4mm Assume the length of
the frame to be: L= 1200mm

From Euler’s formula of crippling load, the polar moment of inertia I is given by:

= ×
×

where: E=modulus elasticity

Esteel= 200-220Gpa (take E =210Gpa)

1066.9N × (1.2m)2
= = 7.42 × 10
× 210 × 109

Where I for square cross section is given by:

I= a4/12

7.42×10−9m4 =a4 /12

, substituting the corresponding values and we get

a=17.27mm

Say; a= 40mm (to make standard) Check

Let’s check the value of the normal stress with the allowable one.

1066.3
= = = = 0.667
40 × 40

Since σ is smaller than the allowable stress :( . . = 0.667 < = .

= 98.18 )

63
Therefore, design for buckling is safe. Therefore, the dimensions for the selected cross section will
be 40mm×40mm.

Figure 30 Supporting Structure

3.3.12 Chute

The chute of a thresher is an outlet for the emission of threshed crops or an outlet for the collection
of seed.

3.3.13 Transport Wheels

Threshers are provided with wheels to make movement on the field easier. These wheels are made
mostly with cost iron but new and large capacity threshers are equipped with pneumatic wheels
for better performance during transportation. Transport wheels should not be so small as
movement on the field will be impeded.

3.4 Assembly procedure

Assemble the bed using bolt and nut Assemble right and left support and cover to main bed, using
bolt and nut Assemble lower concave to main support using bolt and nut Place the cylinder beater
up, to the lower concave Place the upper concave and joined to the lower concave using bolt and
64
nut Place blower to the back side of cover Assemble the lead screw and lead screw casing lower
place the lower side of the sieve

1. Tight bolt and nut at all fittings Assemble right and left support and cover to main bed,
using bolt and nut

2. Assemble lower concave to main support using bolt and nut

3. Place the cylinder beater up, to the lower concave

4. Place the upper concave and joined to the

5. lower concave using bolt and nut

6. lower concave using bolt and nut

Figure 31 Assembly drawing of teff thresher with blower machine

65
3.5 Principle of operation

The engine provides the primary motion required to power the machine. The motion and torque
are transmitted via pulleys, V- belts and bearings to the shaft carrying the beater, blower shaft and
lead screw conveyor connected to the blades. Both the drum beater and blower blades rotate in
clockwise direction. The whole cereal crops (together with stems) are introduced into the machine
through the inlet hopper. They reach the rotating drum inside the shelling barrel by gravity. The
drum gives continuous impact force on the whole cereal crops, thereby removing the grains and
the chaff. Because the beater is arranged in a spiral form. The whole cereal crops move along the
length of the barrel in the forward direction until they reach the chaff exit spout. Before the whole
cereal crops reaches this point, almost all the grains (seeds) are removed thereby letting the chaff
go out of the machine clean. Due to the impact of the beaters some of the chaff or cobs may broke,
through both broken and whole exit through the exit spout. The air generated by the blower blades
is channeled to flow against the teff grain exit spout via a wire mesh. The air blows off unwanted
chaff that exit together with cereal crop grains thereby keeping the teff grains very clean. The clean
cereal crop then run into the receiver where they are collected for further processing operations.

66
 CHAPTER FOUR

RESULT AND DISCUSSION

4.1 Result

Table 12 Result
No. Required parameter Calculated value Remark

1. Power 6kw

2. Belt length 2m Safe

3. Belt thickness 11mm Safe

4. no of belts 2

5. Pulley diameters 400mm ,100mm Safe

7. Shaft diameter 25mm Safe

8. Shaft length 1m Safe

9. Length of key 30mm Safe

10. thickness of key 8mm Safe

11. width of key 10mm Safe

12. drum length 800mm Safe

13. drum diameter 400mm Safe

14. beater diameter 15mm Safe

15. beater length 65mm Safe

16. bore diameter of bearing 25mm Safe

17. outside diameter of bearing 62mm Safe

18. width of bearing 17mm Safe

19. height of support frame 1100mm Safe

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 20. length of support frame 900mm Safe

22. width of sieve 800mm Safe

23. thickness of sieve 1mm Safe

4.2 Discussion on the result

The machine was designed on the basis of the physical and aerodynamic properties of the grain to
be separated and cleaned. The physical attributes and aerodynamic properties of teff grain and the
terminal velocity of the same were obtained from knowing the thickness and width of teff grain
helped the selection of sieve opening sizes required to affect the separation and cleaning of the
grain. The air velocity over the sieve unit was kept close to the terminal velocity of teff grain.
Oscillations of the sieves were made by using a four-bar linkage mechanism where the legs of the
sieve holding frame were pinned and oscillated about a vertical plane. It must be noted that due to
the stacked arrangement of sieves and the drive mechanism employed the horizontal displacements
of the sieves were not the same or equal. By considering physical components, we have not use
gear boxes, and other power transmission mechanism, which are used for transmitting power from
the engine to the gear box. We have used belt system. Since there is a gear box in each thresher, it
makes them more complex to maintenance. Considering manufacturing process, our design is
simple for manufacturing and easy for maintenance. Considering materials used to manufacture
Our design can be manufactured from materials that are locally available and easily accessible.
Considering cost Combiner are much expensive than that of our design, since combiner have a
greater number of components than that of our design the cost for those components make them
expensive. And since they have gear boxes the cost for both materials and manufacturing process
of the gear boxes make them expensive. The selected material property, function, operation,
availability, cost required etc.

68
 CHAPTER FIVE

COST ESTIMATION
5.1 Row material cost

Raw materials cost identifies the price of each initial raw material which will be used in the
manufacturing of the parts and features of the adaptation, designed and manufacturing of teff
threshing machine. The table below gives estimation of the unit and total prices of each required
raw material in accordance with their existing market price.

Table 13 Raw material

Material Dimension/ Quantity Unit Total Remark

type
No.

specification Price in Price in

unit
ETB ETB
Sheet metal 2000*1000*4m 2 2500.00 5000.00
m
1

pcs

Round bar ∅30 ∗ 6000 1 2000.00 2000.00

2

pcs

Round bar ∅20 ∗ 6000 1/5 1100.00 550.00

3

pcs

Round bar ∅8 ∗ 6000 2 600.00 1200.00

pcs
4

Bar ∅8 ∗ 6000 2 250.00 500.00

5

pcs

RHS 40*40*4mm 1 700.0 700.00

6

pcs

69
 RHS 60*60*3mm 1 900.00 900.00

pcs
8 Angle iron 40*40*4mm 1 950.00 950.00

pcs
Flat iron 40*40*4mm 1.5 800.00 1200.00
9

pcs
Total raw material cost 13000.0
0

5.2 Standard components costs

The competitive nature of the manufacturing industry means that companies are constantly looking
for ways to increase the efficiency and productivity of their systems.

Standard components

It is common practice in modern manufacturing for the production of the components that make
up a product to be outsourced to other companies.

The advantage with using standard components is that it speeds up manufacturing and reduces
manufacturing and maintenance costs, as the same units can be purchased and used all around the
world.

Advantages of using standard components

1. Standard components can be manufactured in vast quantities, keeping costs down.

2. Standard components are supplied in standard sizes. Consequently, they are easy to order.
Ordering of standard components is relatively straightforward, sizes / dimensions etc... Are
available in table or index form.

70
3. Buying directly from suppliers, over the counter, at hardware stores such as B & Q, is
easier as standard components such as screws, bolts, nails and fixings are often displayed
in order. This makes it easier to find the component the customer requires.

4. Safety / quality testing is easier when dealing with standard components. Often a number
of standard components, from a batch will be tested. Faulty components can be withdrawn
from sale, if detected.
5. Manufacturers of „complex‟ products (computers TVs, etc.), usually assemble their
products
6. from standard components. This allows them to concentrate on the development of their
specialized product, rather than having to design each individual component. This speed
up product development.
7. Setting up a mass production line is easier if standard components are used. It is easier to
train staff / the workforce, as they are dealing with the same standard components, when
assembling products.
8. Purchasing of standard elements which does eliminate the effort to design and
manufacturing of them, the standard components used in adapting, design and fabrication
of multipurpose machine are listed below as the current market cost.

71
 Table 14 Cost of standard component

No. Part name Quantity Unit cost in Total cost in Remark

ETB ETB

1 Bolt and nutM14*10 10 12.00 120.00

2 Bolt and nutM12*10 10 11.00 110.00

3 Bolt and nutM10*10 10 10.00 100.00

4 Bearing with house∅30 8 220.00 1760.00

5 Drill beat∅30 2 30.00 60.00

6 Drill beat∅13 2 13.00 26.00

7 Drill beat∅12 2 12.00 24.00

8 End mill cutter∅8 2 30.00 60.00

9 End mill cutter∅6 2 25.00 50.00

10 Belt AA68 1 60.00 60.00

11 Belt A65 1 50.00 50.00

12 Belt A40 1 40.00 40.00

13 Electric/engine motor 1 30,000.00 60,000.00

9hp
14 Wheel 2 3000 6000

15 V- belt 3 200 600

16 Pulley 3 500 1500

17 Total cost of standard 70,560.00

ETB

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5.3 Cost summary

Table 15 Summary of cost

No. Type of cost Total cost (ETB)

1 Raw material cost 130,000.00

2 Standard cost 70,560.00

3 Estimated Machining cost 55,00.00

4 Estimated labor cost 7,500.00

Total cost 96560.00 ETB

73
 CHAPTER SIX

CONCLUSION AND RECOMMENDATION

6.1 Conclusion
It is with full confidence to say that this machine will do effectively and lighten the burden of our
farmer’s duties if it is properly manufactured with the described design specifications. The
machine described in this project will effectively thresh and clean Teff using a power of 6kw with
750 rpm of engine speed. This Teff thresher with blower machine is designed and fabricates to
provide all the necessary equipment such as: different pulley diameters, different size round whole
sieves and some necessary dimensions with three number of belt strands. This machine is suitable
for all farmers in Ethiopia who are suffering with traditional way of threshing and blowing device.
The machine is suited completely for production by 'village technology' methods, since no
components require high levels of technical equipment and skill. It would appear that the use of a
Teff thresher with blower machine multiplies labor productivity by a factor of 3 or more over
hand/traditional/ threshing and blowing device. The thresher performance better, can get an
increase drum speed and feed rate, this means the through put of the thresher was best at the highest
threshing/ shelling speed and it requires at least four persons to operate during threshing. Because
an increase engine or motor power it also through put capacity. That means it depends on the feed
rate of the person who put the weight of whole crop material fed into the thresher hopper. The
appearance of the machine seems very huge due to the inclusion of the step sieves which take large
space, which open the way for improvement or modification to down size of the machine. Our
design is done on certain reasonable assumptions such as drum dimension, small pulley dimension,
number of scoopers, beater dimension etc. so that these concepts should be carefully taken in to
consideration as they bring significant change in the overall performance of the teff thresher with
blower machine

74
6.2 Recommendation
 During fabrication and installation of the machine components great care should be taken
to maintain the results of the design.
 The uniformity of feed materials into the cleaning unit was not consistent; hence an
automatic feeding must be developed and used;
 The thresher should be operated at recommended speed and do not drop the cereal when
the machine is not running because it may happen grain damage and power interruption.
 Field testing and promoting rural farmers for the awareness of the machine

75
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Appendix A
Part drawing

79
80
81
82
83
84
85
86
87
Assembly Drawing

88
Appendix B

Appendix tables

Appendix Table 1 Effect of interaction of sieve slope, sieve oscillation and feed rate on cleaning
and separation efficiencies and associated losses

89
Appendix Table 2 Coefficient of friction between belt and pulley [18]

Pulley materials
Belt material Cast iron, steel wood Leather

90
 Dry Wet Greasy
Leather oak tanned 0.25 0.2 0.15 0.3 0.38
Leather chrome 0.35 0.32 0.22 0.4 0.48
tanned
Canvass –stitched 0.20 0.15 0.12 0.23 0.27
Rubber 0.30 0.18 - 0.32 0.40
Balata 0.32 0.20 - 0.35 0.40
Source: [9] and [18]

Appendix Table 3. Tables of means of efficiencies and losses at each level

of factors[24]

Separation efficiency

SS 0 5 10
64.72 73.37 61.39
SO 5 10 15 20
86.97 80.43 58.96 39.62
FR 3 6 9 12
Separation loss

SS 0 5 10
12.95 10.20 18.08
SO 5 10 15 20
4.93 11.19 16.20 22.64
FR 3 6 9 12

Cleaning efficiency

SS 0 5 10
70.68 77.63 58.17
SO 5 10 15 20
89.65 75.39 63.71 46.55
FR 3 6 9 12
Cleaning loss

SS 0 5 10
16.37 12.17 23.75
SO 5 10 15 20
91
 5.41 13.42 20.10 30.81
FR 3 6 9 12
9.13 12.62 20.35
27.63

Appendix Table 4, some specification of A-type v-belt

Appendix Table 5 perforated plate sieves dimension [22]

92
93
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