Detailed analysis

1. 1
CHAPTER 1
INTRODUCTION
Sugarcane is an oldest crop known to man, a major crop of tropical and sub-tropical regions worldwide.
Sugarcane is a glycophyte, sucrose storing member of tall growing perennial monocotyledonous grass.
Across the world 70% sugar is manufactured from sugarcane. India is the second largest country in
sugarcane production in the world. Sugarcane is a major source of raw material for sugar industries and
other allied group of by-product industries. The economic importance of the crop is much more that
signified by its share in gross cropped area. The world economy is currently dominated by technologies
which rely on fossil energy and this will remain the case for much of the 21st century. Recognition of
sugarcane as an important energy crop was recently heightened by the advent of large-scale sugarcane-
based ethanol production from molasses and directly from cellulose. Sugarcane is one the most efficient
crops in the world in converting solar energy into chemical energy. Sugar cane is the most efficient
biofuel feedstock in commercial use today and sugar cane ethanol will contribute to reduce greenhouse
gas up to 90% compared to conventional fuels. It is also being used as a feedstock for the next generation
of advanced bio-fuels, such as bio-butanol and diesel and many other valuable by-products through
sugarcane biotechnology (Yadav and Solomon, 2006; Solomon, 2011a). Apart from production of sugar
and alcohol (biofuel), sugar industry provides raw material to more than 25 other industries. The
important by-products of this industry are acetic acid, butanol, paper, plywood and industrial enzymes
(Arencibia, 1998).
Sugarcane plays a major role in the economy of sugarcane growing areas and, hence, improving
sugarcane production will greatly help in economic prosperity of the farmers and other stakeholders
associated with sugarcane cultivation. There has been tremendous awareness in the area of developing
"Sugar Complexes" focusing on economic and sustainable utilization of sugar industry by-products. In
India, many sugar units have transformed themselves into Sugar-Agro industrial Complexes, producing a
variety of chemicals and utility products from sugarcane. Sucrose content is the highly desirable trait in
sugarcane as the worldwide demand for cost-effective bio-fuels is increasing. Sugarcane‟s high
efficiency in fixing CO2 into carbohydrates for conversion into biofuel has awakened the world‟s interest
in the crop.
The Indian sugar industry is second largest industry in the country, generates surplus exportable power
through cogeneration thereby playing a major catalytic role in the socioeconomic transformation of rural
population. It encompasses 599 operating sugar mills, 309 distilleries, 180 co-generation, numerous
paper and pulp plants (Solomon, 2011b). There will be high demand for sugarcane as a source of biofuel;
power and sugar which is going to contribute national economy in a greater way.

2. 2
In India, for conventional system of sugarcane cultivation, about 6 – 8 tones seed cane /ha is used as
planting material, which comprises of about 32,000 stalk pieces having 2-3 buds. Cane cuttings with one,
two or three buds known as sets are used as seed. This large mass of planting material poses a great
problem in transport, handling and storage of seed cane and undergoes rapid deterioration thus reducing
the viability of buds and subsequently their sprouting. One alternative to reduce the mass and improve
the quality of seed cane would be to plant excised axillary buds of cane stalk, popularly known as bud
chips. These bud chips are less bulky, easily transportable and more economical seed material. The bud
chip technology holds great promise in rapid multiplication of new cane varieties. The left-over cane can
be well utilized for preparing juice or sugar or jiggery.[1]
1.1 Planting Material:-
Sugarcane is vegetatively propagated for commercial cultivation. Different kinds of planting materials
viz., cane setts; settlings and bud chips are used for raising sugarcane crop.
Sugarcane Bud:
Little portion of stem with one bud is known as bud chip. Bud chips are used to raise settlings in nursery.
They were found to produce a good crop when transplanted in main field. The principal advantage of bud
chips is substantial saving in seed material. Seed requirement is reduced to less than one ton per ha.
Figure 1:Single bud settling
Adopting the following procedure raises settlings from bud chips. Adopting the following procedure
raises settlings from bud chips:
 Prepare the bud chips from whole cane using a sharp edged knife in such a way that each bud has
a little portion of stem.

3. 3
 Plant the bud chips on raised nursery beds adopting a inter-row spacing of 7.5 cm at the rate of
300 buds/m2.
 Alternatively nursery can be raised in polybags of 15 cm x 10 cm size.
 Fill the polybags with homogeneous mixture of equal quantity of soil, sand and well rotten
compost.
 Plant the bud chips in polybags with the bud facing upwards and cover with soil mixture to avoid
drying of the bud.
 Bottom of the bags should have holes to facilitate drainage.
 Ensure regular watering of bags or nursery area.
 Settlings are ready in 5 - 8 weeks for transplanting in the main field.
 Under good management conditions establishment of transplanted seedlings in the main field is
high (90-100%).[2]
1.2 NEED FOR BUD CHIPPER:
The need for sugar cane bud chipper is only for the farmers, where they are using an full size of
sugarcanes in the field for the plantation purpose, while using this sugar cane bud chipper we can cut it
down in to small pieces, compact in size it can also be used for plantation from this we save the wastage
of remaining portion of the sugar cane.
Figure 2: Traditional method

4. 4
Figure 3: Bud chipping method

5. 5
CHAPTER 2
LITERATURE SURVEY
2.1 Research paper number 1:
Low Cost Sugarcane Bud Chipper
M.D.Raj Kamal, S.Asswin, C.Balamurugan, N.G.Jeeva, A.P. Revanth Raam, Department of Mechanical
Engineering, Velammal Institute of Technology, India
M.D.Raj Kamal, S.Asswin, C.Balamurugan, N.G.Jeeva, A.P. Revanth Raam published a paper on Low
cost sugarcane bud chipper. In this research paper they have proposed a sugarcane bud chipping machine
which is being operated by a motor. By doing this they are reducing human effort to cut the buds.[1]
They had studied that the project aims to design and fabricate semi-automated sugarcane bud chipping
machine for agriculture, to reduce farmer‟s efforts and to increase production of agriculture products. In
this machine two operations are carried out at a time. The operations that can be carried out on this
machine are sugarcane internode cutting and sugarcane bud scooping. In sugarcane internode cutting
operation, sugarcane is cut at its nodal part in small pieces and in the sugarcane bud scooping operation
eye bud is scooped out from the sugarcane for the seedling purpose. This operation is mainly based on
worm and worm gear mechanism.[3]
Components Used:-
 Single Phase Ac Induction motor.
 A Gear combination consisting,
 Worm Gear- 3 teeth
 Helical Gear- 30 teeth
 Helical Gear- 15 teeth
 Helical Gear- 70 teeth
 Circular Disc.
 Shaft.
 M8 Bolt.
 Plate (Mild Steel) and Pillar (M12 Bolt)
 Cutter (MS Pipe)

6. 6
Layout:-
Figure 1: Isometric view of bud chipping machine
Working:
 When the Single phase Ac induction motor is switched on, it starts to run at a speed of over 1400rpm.
This 1400 rpm is given at the end of Worm gear.
 The worm gear is further connected to a helical gear of consisting of 30 teeth which is further
connected to two helical gears and these gears operate in combination to reduce the speed from 1400
rpm to 30 rpm.
 Hence due to gear reduction the speed reduces down to 30 rpm. Now this speed is fed to the circular
disc which is connected to the motor through a slot joint.
 This disc further has a shaft connected to it. As the motor gives a 30 rpm output, the disc also rotates
at a speed of 30 rotations per minute.
 The shaft also rotates along with the disc.
 During the rotation, as the shaft comes down the Top plate of the plate-pillar assembly moves down.
The Top plate also consists of the cutter.
 Thus the cutter moves down and cuts the bud from the sugarcane.
 As the disc further rotates, the shaft moves up and hence the top plate is released and hence it moves
up.
 When the shaft again comes down the pressing action is repeated and eventually the cutting operation
is repeated.
 By this method, rotary motion of the motor is converted and delivered as reciprocating motion at the
cutter end and eventually the removal of bud is also achieved at a rate of 30 per minute.

7. 7
2.2 Research paper number 2 :
Design and Fabrication of Sugarcane Bud Cutting Machine
Krishna Prasads, Harish Kumar H. R , Harsha B. G , Harshith .S , Kishan Kumar, Department of
Mechanical Engineering Maharaja Institute of Technology, Mysore, India
They studied that in tradition planting method, great human force and high volume of sugarcane stalk in
hectare are required. The project aims to design and fabricate pedal operated sugarcane bud chipping
machine for agriculture. In this method the sugarcane is fed to the cutting region manually. This machine
removes the buds by cutting the node as well as scooping out the bud from the cane simultaneously. This
operation is mainly based on chain and sprocket mechanism.
Working principle:-
Working Principle Sugarcane bud chipper machine works on Rotary mechanism. Figure 2 shows an
electric motor is coupled to a speed reducer worm gearbox. The high speed-low torque rotary power
from the electric motor is converted into low-speed high torque power output using a worm gearbox and
it is made available at the shaft to which the blades are fixed through the chain drive. The cutting action
of blades takes place due to the rotary motion of the blades in conjunction with the contour of the blade
itself. The operator has to manually feed the sugarcane stalk in an axial direction with respect to the
rotation of the blades. The blade design and machine setup are designed so that for each rotation of
blades, one bud from the stalk is cut and in the next rotation of the blades, the next bud is cut and so on.
i.e., for each rotation, each bud from the sugarcane stalk is being cut.[4]

8. 8
CHAPTER 3
SEMI-AUTOMATIC SUGARCANE BUD CHIPPING MACHINE
3.1 Working mechanism:
 When the Single phase Ac induction motor is switched on, it starts to run at 1400 rpm.
 Speed is reduced by the belt and pully drive to 700 rpm.
 This speed is transmitted to the gear box which contains worm and worm wheel drive which has gear
ratio of 1:30.
 Now speed is reduced to 23 rpm. A cam is connected to gear box which convert rotary motion into
reciprocating motion of cutter.
 When cutter moves in forward direction it cuts the sugracane bud which is manually feeded.
 When cutter moves in backward direction it release sugarcane bud and these buds are collected in
collector.
 By this method, rotary motion of the motor is converted and delivered as reciprocating motion at the
cutter end and eventually the removal of bud is also achieved.
3.2 Components required:
 Power source (Motor)
 Gear box
1.Worm and worm wheel
 Shaft
 Cutter
 Belt drive
 Supporting frame
 Cam

9. 9
3.3 Working model:
Figure 4: Working model of sugarcane bud chipping machine (Top view)
Figure 5:Working model of sugarcane bud chipping machine (Front view)

10. 10
3.4 Specification of components and cost analysis:
Components Material used Specification Unit price(in RS) Total price(in RS)
Motor .5 HP, 1400 rpm 3200 3200
Gear box Gear ratio 1:30 2150 2150
Pulley (2) Cast iron D1=50 mm
D2= 100 mm
150 300
Flat belt Leather L=760 mm
b= 13 mm
t=5 mm
200 200
Shaft Mild steel Dia =25 mm 100 100
Cutter High carbon steel Gap = 30 mm 250 250
Supporting
frame
Mild steel L= 1000 mm
B=400 mm
H=450 mm
600 600
Cam Mild steel Dia=10 mm 200 200
Total 7000 /-

11. 11
CHAPTER 4
DESCRIPTION AND SPECIFICATION OF COMPONENTS
4.1 Components :
4.1.1 Power source (Motor):- Electric motor is an electrical machine that is used to convert electrical
energy into mechanical energy. Although traditionally used in fixed-speed service, induction motors are
increasingly being used with variable-frequency drives in variable-speed service. VFDs offer especially
important energy savings opportunities for existing and prospective induction motors in variable-torque
centrifugal fan, pump and compressor applications.
Power of motor = 0.5 hp
Speed of motor =1400 rpm
Figure 6:Electric motor

12. 12
4.1.2 Gear Box:
Gearbox is used to reduce speed of shaft and to control the rotation motion. Most modern gearboxes are
used to increase torque while reducing the speed of a prime mover output shaft. This means that the
output shaft of a gearbox rotates at a slower rate than the input shaft, and this reduction in speed
produces a mechanical advantage, increasing torque. Some of the simplest gearboxes merely change the
physical rotational direction of power transmission. Worm and worm gear box is used to transmit the
output power. A gear box designed using a worm and worm-wheel is considerably smaller than one
made from plain spur gear, and has its drive axes at 90° to each other. With a single start worm, for each
360° turn of the worm, the worm-gear advances only one tooth of the gear.
Gear ratio = 1:30
Figure 7: Gear Box
4.1.3 Gear Drive:
Gears are toothed members which transmit power / motion between two shafts by meshing without any
slip. Hence, gear drives are also called positive drives. In any pair of gears, the smaller one is called
pinion and the larger one is called gear immaterial of which is driving the other.[5]
Types of gear drive:
1. Spur Gears
2. Helical Gears
3. Double Helical Gear Or Herringbone Gear

13. 13
4. Internal Gear
5. Rack And Pinion
6. Straight Bevel Gear
7. Spiral Bevel Gear
8. Hypoid Bevel Gear
9. Worm Gear
10. Spiral Gear
1. Spur Gear:
Spur gears have their teeth parallel to the axis and are used for transmitting power between two parallel
shafts. They are simple in construction, easy to manufacture and cost less. They have highest efficiency
and excellent precision rating. They are used in high speed and high load application in all types of trains
and a wide range of velocity ratios.
Figure 8:Spur Gear
2. Helical Gears:
Helical gears are used for parallel shaft drives. They have teeth inclined to the axis. Hence for the
same width, their teeth are longer than spur gears and have higher load carrying capacity. Their contact
ratio is higher than spur gears and they operate smoother and quieter than spur gears. Their precision
rating is good. They are recommended for very high speeds and loads.

14. 14
Figure 9:Helical Gear
3. Double Helical Gear Or Herringbone Gear
Double helical or Herringbone gears used for transmitting power between two parallel shafts. They have
opposing helical teeth with or without a gap depending on the manufacturing method adopted, Fig. 1.11.
Two axial thrusts oppose each other and nullify. Hence the shaft is free from any axial force. Though
their load capacity is very high, manufacturing difficulty makes them costlier than single helical gear.
Their applications are limited to high capacity reduction drives like that of cement mills and crushers.
Figure 10:Double Helical Gear

15. 15
4. Internal Gear:
Internal gears are used for transmitting power between two parallel shafts. In these gears, annular wheels
are having teeth on the inner periphery. This makes the drive very compact. In these drives, the meshing
pinion and annular gear are running in the same direction.
Figure 11:Internal Gear
5. Rack And Pinion:
Rack is a segment of a gear of infinite diameter. The tooth can be spur or helical. This type of
gearing is used for converting rotary motion into translatory motion or visa versa.
Figure 12:Rack and Pinion

16. 16
6. Straight Bevel Gear:
Straight bevel gears are used for transmitting power between intersecting shafts. They can operate under
high speeds and high loads. Their precision rating is fair to good. They are suitable for 1:1 and higher
velocity ratios and for right-angle meshes to any other angles. Their good choice is for right angle drive
of particularly low ratios. However, complicated both form and fabrication limits achievement of
precision. They should be located at one of the less critical meshes of the train. Wide application of the
straight bevel drives is in automotive differentials, right angle drives of blenders and conveyors.
Figure 13:Straight Bevel Gear
7. Spiral Bevel Gear:
Spiral bevel gears are also used for transmitting power between intersecting shafts. Because of the spiral
tooth, the contact length is more and contact ratio is more. They operate smoother than straight bevel
gears and have higher load capacity. But, their efficiency is slightly lower than straight bevel gear. Usage
of spiral bevel gears in an automobile differential.

17. 17
Figure 14:Spiral Bevel Gear
8. Hypoid Bevel Gear:
These gears are also used for right angle drive in which the axes do not intersect. This permits the
lowering of the pinion axis which is an added advantage in automobile in avoiding hump inside the
automobile drive line power transmission. However, the non – intersection introduces a considerable
amount of sliding and the drive requires good lubrication to reduce the friction and wear. Their efficiency
is lower than other two types of bevel gears. These gears are widely used in current day automobile drive
line power transmission.
Figure 15:Hypoid Bevel Gear

18. 18
9. Worm Gear:
Worm and worm gear pair consists of a worm, which is very similar to a screw and a worm gear, which
is a helical gear. They are used in right-angle skew shafts. In these gears, the engagement occurs without
any shock. The sliding action prevalent in the system while resulting in quieter operation produces
considerable frictional heat. High reduction ratios 8 to 400 are possible. Efficiency of these gears is low
anywhere from 90% to 40 %. Higher speed ratio gears are non-reversible. Their precision rating is fair to
good. They need good lubrication for heat dissipation and for improving the efficiency. The drives are
very compact. Worm gearing finds wide application in material handling and transportation machinery,
machine tools, automobiles etc. An industrial worm gear box used for converting horizontal to vertical
drive.
Figure 16:Worm Gear
10. Spiral Gear:
Spiral gears are also known as crossed helical gears. They have high helix angle and transmit power
between two non-intersecting non-parallel shafts. They have initially point contact under the conditions
of considerable sliding velocities finally gears will have line contact. Hence, they are used for light load
and low speed application such as instruments, sewing machine etc. Their precision rating is poor. An
application of spiral gear used in textile machinery.

19. 19
Figure 17:Spiral Gear
4.1.4 Shaft:
A Shaft is a rotating element, usually circular in cross section; line shaft is used to transmit power from
one shaft to another, or from the machine which produces power, to the machine which absorbs power.
Shaft is used to transmit power from motor to gearbox and from gearbox to mechanism. A shaft is an
element used to transmit power and torque, and it can support reverse bending. Most shafts have circular
cross sections, either solid or tubular. Shafts have different means to transmit power and torque. Shafts
are able to avoid vibration of the elements, and assure an efficient transmission of power and torque,
some changes in the cross-section of the shaft can be made.
Shaft diameter = 25 mm
4.1.5 Cutter:
This is the main section of the scooping machine. The scoop cutter is used to cut the sugarcane bud and
to get the same size of sugarcane bud. Because of scooping cutter the wastage of sugarcane reduces and
safety of farmer increases.
Cutter dimension = 30×30 mm

20. 20
4.1.6 Belt and pulley drive:
A belt is a looped strip of flexible material used to mechanically link two or more rotating shafts. A belt
drive offers smooth transmission of power between shafts at a considerable distance. Belt drives are used
as the source of motion to transfer to efficiently transmit power or to track relative movement.
Two types of belt drives
1. Open belt drive
2. Crossed belt drive
In both the drives, a belt is wrapped around the pulleys. Let us consider the smaller pulley to be the
driving pulley. This pulley will transmit motion to the belt and the motion of the belt in turn will give a
rotation to the larger driven pulley. In open belt drive system the rotation of both the pulleys is in the
same direction, whereas, for crossed belt drive system, opposite direction of rotation is observed.[5]
Nomenclature of Open Belt Drive:
Figure 18:Open Belt Drive
dL - Diameter of the larger pulley
dS – Diameter of the smaller pulley
αL- Angle of wrap of the larger pulley
αs – Angle of wrap of the smaller pulley
C- Center distance between the two pulleys

21. 21
Basic Formulae:
αL = 180ο
+ 2β
αS = 180ο
- 2β
Where angle β is,
Nomenclature of Cross Belt Drive:
Figure 19:Cross Belt Drive
dL - Diameter of the larger pulley
dS – Diameter of the smaller pulley
αL- Angle of wrap of the larger pulley
αS – Angle of wrap of the smaller pulley
C- Center distance between the two pulleys

22. 22
Belt tensions:
The belt drives primarily operate on the friction principle. i.e. the friction between the belt and the pulley
is responsible for transmitting power from one pulley to the other. In other words the driving pulley will
give a motion to the belt and the motion of the belt will be transmitted to the driven pulley. Due to the
presence of friction between the pulley and the belt surfaces, tensions on both the sides of the belt are not
equal. So it is important that one has to identify the higher tension side and the lower tension side.
Figure 20:Tension in Belts
When the driving pulley rotates (in this case, anti-clock wise), from the fundamental concept of friction,
we know that the belt will oppose the motion of the pulley. Thereby, the friction, f on the belt will be
opposite to the motion of the pulley. Friction in the belt acts in the direction and will impart a motion on
the belt in the same direction. The friction f acts in the same direction as T2. Equilibrium of the belt
segment suggests that T1 is higher than T2. Here, we will refer T1 as the tight side and T2 as the slack
side, i.e, T1 is higher tension side and T2 is lower tension side.

23. 23
4.1.7 Supporting frame:
The whole assembly is mounted on this frame. The complete frame is made up of mild steel. To give
sufficient height to machine.
Length of frame = 70 cm
Height of frame = 50 cm
Width of frame = 35 cm

24. 24
CHAPTER 5
DESIGN AND CALCULATION
5.1 DESIGN:
Design consists of application of scientific principles, technical information and imagination for
development of new or improvised machine or mechanism to perform a specific function with maximum
economy & efficiency. Hence a careful design approach has to be adopted. The total design work has
been split up into two parts;
1. System design
2. Mechanical Design
System design mainly concerns the various physical constraints and ergonomics, space requirements,
arrangement of various components on main frame at system, man + machine interactions, No. of
controls, position of controls, working environment of machine, chances of failure, safety measures to be
provided, servicing aids, ease of maintenance, scope of improvement, weight of machine from ground
level, total weight of machine and a lot more.
In mechanical design the components are listed down and stored on the basis of their procurement,
design in two categories namely,
1.Designed Parts
2.Parts to be purchased
For designed parts detached design is done & distinctions thus obtained are compared to next highest
dimensions which are readily available in market. This amplifies the assembly as well as postproduction
servicing work. The various tolerances on the works are specified. The process charts are prepared and
passed on to the manufacturing stage.
The parts which are to be purchased directly are selected from various catalogues & specified so that
anybody can purchase the same from the retail shop with given specifications.
5.1.1 SYSTEM DESIGN:
In system design we mainly concentrated on the following parameters:
A. System Selection Based on Physical Constraints
While selecting any machine it must be checked whether it is going to be used in a large-scale industry or
a small-scale industry. In our case it is to be used by a small-scale industry. So, space is a major

25. 25
constrain. The system is to be very compact so that it can be adjusted to corner of a room. The
mechanical design has direct norms with the system design. Hence the foremost job is to control the
physical parameters, so that the distinctions obtained after mechanical design can be well fitted into that.
B. Arrangement of Various Components
Keeping into view the space restrictions the components should be laid such that their easy removal or
servicing is possible. More over every component should be easily seen none should be hidden. Every
possible space is utilized in component arrangements.
C. Components of System
As already stated the system should be compact enough so that it can be accommodated at a corner of a
room. All the moving parts should be well closed & compact. A compact system design gives a high
weighted structure which is desired.
D. Man-Machine Interaction
The friendliness of a machine with the operator that is operating is important criteria of design. It is the
application of anatomical & psychological principles to solve problems arising from Man – Machine
relationship. Following are some of the topics included in this section.
a. Design of foot lever
b. Energy expenditure in foot & hand operation
c. Lighting condition of machine.
E. Chances of Failure
The losses incurred by owner in case of any failure is important criteria of design. Factor safety while
doing mechanical design is kept high so that there are less chances of failure. Moreover, periodic
maintenance is required to keep unit healthy.
F. Servicing Facility
The layout of components should be such that easy servicing is possible. Especially those components
which require frequents servicing can be easily disassemble.

26. 26
G. Height of Machine from Ground
For ease and comfort of operator the height of machine should be properly decided so that he may not get
tired during operation. The machine should be slightly higher than the waist level, also enough clearance
should be provided from the ground for cleaning purpose.
H. Weight of Machine
The total weight depends upon the selection of material components as well as the dimension of
components. A higher weighted machine is difficult in transportation & in case of major breakdown; it is
difficult to take it to workshop because of more weight.[6]
5.1.2 MECHANICAL DESIGN:
DESIGN CALCULATIONS:
Known data:
Force required to cut the bud of sugarcane F= 400 N [6]
(The average force for punching from the literature.)
Bud cutting frequency = 23 bud / min
Belt specification:
ρ =0.95 g/cm3
µ =0.35
t = 5 mm
b = 13 mm
Permissible stress:
σ =2.45 N/mm2
centre distance of belt = 250 mm
width of belt =13 mm
thickness =5 mm

27. 27
N2 /N1= 30:1
So,
N2=N1 ×30
N2=23 ×30
N2=690rpm
D2=100 mm
W = 2 N
V=πD2N2/1000×60
V=(π×10×100×690)/1000×60
V= 3.611m/s
Length of belt:
L=2C+ (π(D1+D2))/2+ (D2-D1)2
/4C
L=2×250+ (π(64.28+100))/2+ (100-64.28)2
/(4×250)
L=759.1955 mm
Angle of lapping between belt & pulley :
α=180-2 sin-1
(D2-D1)/2C
α=180-2 sin-1
(100-64.28)/(2×250)
α=171.8060
α=171.806/180×π
α=2.997 rad

28. 28
Volume of belt:
V=l×b×t
V=100×13/10×5/10
V=65 cm3
Mass of belt:
m=0.95×65 gm
m=0.95×65/1000 kg
m=0.06175 kg
mv2
=0.06175 × 3.6112
mv2
=0.80522
e(µ×α )= e(0.35×2.997 )=2.854
(T1-mv2
)/(T2-mv2
)= e(µ×α )
=2.854
(T1-0.80522)/(T2-0.80522)= e(µ×α )
=2.854
Max permissible stress in the belt:
σ= T1/A
T1= σ ×A
T1= 2.45 ×5×13
T1= 159.25N
So,
T2= 55.798N
P=(T1-T2)×V
P=373.5 W

29. 29
Torque Calculation:
Torque formula:
P = (2×3.14×N×T)/60
where, P stands for Power, N stands for Speed, T stands for Torque.
Torque in the motor before speed reduction,
P = (2 x 3.14 x N3 x T3)/60
373= (2 x 3.14 x 1400 x T1)/60
Hence,
T3 = 2.54 (Nm)
We know that,
T3 x N3 = T2 x N2
Hence,
T2 = (T3 x N3)/N2
Thus, T2 = (2.54 x 1400)/ 690 =5.08 N-m
Assuming the transmission efficiency is 82% hence, T2=5.08 x 0.82 Hence,
T2 = 4.16 N-m
For gear box:
T2 x N2= T1 x N1
4.16 x 700= T1 x 23
T1= 126.6 N-m
Design of shaft:-
Total vertical load acting on the pulley:
Wt = T1 + T2 +W

30. 30
= 159.25 + 55.798 + 2
= 217.04
M= Wt × L
=217.048 × 50
=10852.4 N-mm
Twisting moment acting on the shaft:
T= 4160 N-mm
Equivalent twisting moment:
√
√
= 11622.40 N-mm
σyt = 250 N/mm2
fos = 4
τyt = 0.5 × σyt
= 125 N/mm2
τw =125/4
= 31.25 N/mm2
τw = 16 Te /π d3
d= (16 × 11622.40)/π × 31.25
= 12.37 mm
= 13 mm
As we are using 25 mm dia. shaft. So our design is safe.
Cutter Design:
τyt = 125 N/mm2
F= the average force for punching from the literature and the experiment is 400N.
τyt = F/A
= 400/2 × (π D2
/4)
= 400/2 × (π 252
/4)
= 0.4076 N/mm2
Since, τ << τyt
Hence design is safe under shear.[4]

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CHAPTER 6
FABRICATION ASPECTS OF THE WORKING MODEL
6.1 Electric Arc Welding:
Arc welding is the fusion of two pieces of metal by an electric arc between the pieces being joined – the
work pieces – and an electrode that is guided along the joint between the pieces. The electrode is either a
rod that simply carries current between the tip and the work, or a rod or wire that melts and supplies filler
metal to the joint.
The basic arc welding circuit is an alternating current (AC) or direct current (DC) power source
connected by a “work” cable to the work piece and by a “hot” cable to an electrode. When the electrode
is positioned close to the work piece, an arc is created across the gap between the metal and the hot cable
electrode. An ionized column of gas develops to complete the circuit.[7]
Figure 21 Electric arc welding
6.1.1 Welding electrode specification:
The American Welding Society (AWS) numbering system can tell a welder quite a bit about a specific
stick electrode including what application it works best in and how it should be used to maximize
performance. With that in mind, let's take a look at the system and how it works.

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The prefix "E" designates an arc welding electrode. The first two digits of a 4-digit number and the first
three digits of 5-digit number indicate minimum tensile strength. For example, E6010 is a 60,000 psi
tensile strength electrode while E10018 designates a 100,000 psi tensile strength electrode.
The next to last digit indicates position. The "1" designates an all position electrode, "2" is for flat and
horizontal positions only; while "4" indicates an electrode that can be used for flat, horizontal, vertical
down and overhead. The last 2 digits taken together indicate the type of coating and the correct polarity
or current to use.
6.2 Machining:
Machining processes, which include cutting, grinding, and various non-mechanical chipless processes,
are desirable or even necessary for the following basic reasons: (1) Closer dimensional tolerances,
surface roughness, or surface-finish characteristics may be required than are available by casting,
forming, powder metallurgy, and other shaping processes; and (2) part geometries may be too complex
or too expensive to be manufactured by other processes. However, machining processes inevitably waste
material in the form of chips, production rates may be low, and unless carried out properly, the processes
can have detrimental effects on the surface properties and performance of parts.
6.2.1 Turning :
Turning in a lathe is to remove excess material from the work piece to produce a cylindrical surface of
required shape and size.

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Figure 22:Straight Turning
6.2.2 Grinding:
Grinding is the most common form of abrasive machining. It is a material cutting process which engages
an abrasive tool whose cutting elements are grains of abrasive material known as grit. These grits are
characterized by sharp cutting points, high hot hardness, and chemical stability and wear resistance. The
grits are held together by a suitable bonding material to give shape of an abrasive tool.
Figure 23:Grinding process
Grinding Wheel Specification:
The standard marking system for conventional abrasive wheel can be as follows:
51 A 60 K 5 V 05,
Where,
1. The number „51‟ is manufacturer‟s identification number indicating exact kind of abrasive used.

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2. The letter „A‟ denotes that the type of abrasive is aluminium oxide. In case of silicon carbide the
letter „C‟ is used.
3. The number „60‟ specifies the average grit size in inch mesh. For a very large size grit this number
may be as small as 6 whereas for a very fine grit the designated number may be as high as 600.
4. The letter „K‟ denotes the hardness of the wheel, which means the amount of force required to pull
out a single bonded abrasive grit by bond fracture. The letter symbol can range between „A‟ and „Z‟,
„A‟ denoting the softest grade and „Z‟ denoting the hardest one.
5. The number „5‟ denotes the structure or porosity of the wheel. This number can assume any value
between 1 to 20, „1‟ indicating high porosity and „20‟ indicating low porosity.
6. The letter code „V‟ means that the bond material used is vitrified. The codes for other bond materials
used in conventional abrasive wheels are B (resinoid), BF (resinoid reinforced), E(shellac),
O(oxychloride), R(rubber), RF (rubber reinforced), S(silicate)
7. The number „05‟ is a wheel manufacturer‟s identifier.
Major advantages and applications of grinding:
Advantages:
1. Good dimensional accuracy
2. good surface finish
3. good form and locational accuracy
4. applicable to both hardened and unhardened material
Applications:
1. Surface finishing
2. Slitting and parting
3. Descaling, deburring
4. Stock removal (abrasive milling)
5. Finishing of flat as well as cylindrical surface
6. Grinding of tools and cutters and resharpening of the same
Conventionally grinding is characterized as low material removal process capable of providing both high
accuracy and high finish. However, advent of advanced grinding machines and grinding wheels has
elevated the status of grinding to abrasive machining where high accuracy and surface finish as well as
high material removal te can be achieved even on an unhardened material.

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Figure 24: Elevation of the status of grinding to abrasive machining
Bench grinding Machine:
Figure 25:Bench Grinding Machine
Bench grinding procedure:
 Allow grinder to reach full rpm before grinding,
 Position yourself to avoid overbalancing,
 Firmly grip object to be ground,
 Keep hands and fingers clear of abrasive wheels,
 When grinding avoid placing excessive pressure on abrasive wheels,
 Grind object evenly across entire abrasive wheel face,
 Do not grind objects on sides of grinding wheels,Materials may become hot when grinding – use
gloves when necessary.

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6.2.3 Boring:
In machining, boring is the process of enlarging a hole that has already been drilled (or cast) by means of
a single-point cutting tool (or of a boring head containing several such tools), such as in boring a gun
barrel or an engine cylinder. Boring is used to achieve greater accuracy of the diameter of a hole, and can
be used to cut a tapered hole. Boring can be viewed as the internal-diameter counterpart to turning, which
cuts external diameters.[6]

Figure 26:Boring Operation

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CHAPTER 7
ADVANTAGES AND CHALLENGES
7.1 Advantages:
i. Human effort is reduced.
ii. Wastage of sugarcane is reduced.
iii. These bud chips are less bulky so transportation of chips is easy.
iv. Less time is used as compared to conventional process.
v. Easy to operate.
vi. Labor cost is reduced.
vii. High cutting speed and more number of buds can be cut.
viii. Reduces the plantation cost.
ix. Noiseless
x. Only about 240kg of seeds are required per acre against of 2-4 tons of sugar cane in normal planting.
xi. The sugarcane after taking buds can be sent for milling or to juice center.
xii. Injuries caused during normal operation is eliminated.
7.2 Challenges:
i. Automatic feeding is difficult.

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CHAPTER 8
INCOME FOR FARMERS THROUGH OUR MACHINE
Based on the case study that we performed during the time of developing this machine‟s design, we
collected certain data related to the conventional sugarcane cultivation method and our method of
cultivating sugarcane. In conventional method about 36000 whole sugarcane pieces are required to be
planted for cultivating sugarcane in one acre of land. However in our method only 36000 sugarcane buds
are required for the same purpose and not whole piece of sugarcane. Therefore the saved parts of
sugarcane can be sold to vendors in market which acts as an added source of income for the farmer. It is
estimated that the profit that can be earned through this way is about Rs 11,433.
Here is the detailed calculation,
Conventional method:
36,000 pieces of sugarcane is required for cultivation (One acre).
1 Ton=6,750 pieces
Hence, 5.2 ton of Sugarcane pieces used (One acre).
Our method:
36,000 buds used for cultivation (One acre).
36,000 buds= 1.5 ton
Left out sugarcane pieces weight = 3.7 Tons
1 Ton sugarcane= Rs 3,090
Hence, 3.7x3090= Rs 11,433
This is the Profit that can be earned by the farmer.
Cost Comparison:
The following are the data associated with conventional and our method of sugarcane cultivation.
Conventional method:
Amount to be invested to buy sugarcane = Rs 14,820 per acre.
Amount collected as Revenue = Rs 1.42 L per acre

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Our method:
Based on our estimation, our machine will cost about Rs 7000.
Amount to be invested =Rs 14820(per acre) + Rs 7000(first year only) = Rs 20820.
Amount collected as Revenue = Rs 1.53 L per acre
Therefore based on the above data it can be seen that a profit of Rs 4,433 can be earned by the farmer in
the first year,
And in the successive years a profit of Rs 11,433 can be obtained per year.
Figure 27:Investment Comparison Graph

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Figure 28: Revenue Comparison Graph

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CHAPTER 9
CONCLUSION
We implement the human powered sugarcane bud chipping machine to overcome all this problems
faced by people in rural areas we suggest the development and modification of existing machine. We
reduced the problems related to chipping operation like wastage of sugarcane, effort required is
more, time consumed is more and production rate is less. All these problems are being eliminated
and this machine can be successfully implemented for the increase in the production rate of the bud,
since two buds are being cut in single cycle hence time required for cutting each bud will be
reduced. Also sugarcane wastage is reduced because of proper installation of clamping to hold the
sugarcane.
By providing high profits at low investment and also by simplifying bud removal process along with
minimizing labour requirement, our machine proves to be a highly profitable investment for farmers
and breakthrough in farming technology.

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REFERENCES
1. International Journal of Advance Engineering and Research Development (IJAERD) Volume
5, Issue 03, March-2018, e-ISSN: 2348 - 4470, print-ISSN: 2348-6406.
2. Ningappa H Kuri, Prof.Reddy Naik.J Design and Development of Sugar Cane Bud
Chipping Machine ISSN 2321-304, 2016.
3. H. Bakker (1999) Sugar Cane Cultivation and Management The ChronicaBotanica Co.: Book
Department, Waltham ISBN-0306461196.
4. International Journal of Advance Engineering and Research Development (IJAERD) Volume
5, Issue 03, March-2018, e-ISSN: 2348 - 4470, print-ISSN: 2348-6406.
5. V B Bhandari, “Design Of Machine Elements”, 2013.
6. “Design And Modification Of Sugarcane Bud Scooping Machine” IRJET: International
Research Journal of Engineering and Technology e-ISSN: 2395 -0056 Volume: 03 Issue: 04 |
April-2016 www.irjet.netpISSN: 2395-0072.
7. P.N. Rao , “manufacturing science volume 2”, 2016.

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