Design and Fabrication of Pedal operated Flour Mill

Design andFabrication ofPedal operatedFlour mill
DEPARTMENT OF MECHANICAL ENGINEERING, BCE, SHRAVANABELAGOLA. 1
DESIGN AND FABRICATION OF PEDAL OPERATED
FLOUR MILL
AIM:
To design and fabricate pedal operated flour mill.
SCOPE:
 To get the very fine flour without using electricity.
 To design an Eco friendly product.
 Easy to operate.
 To use as alternative source when electricity supply was not there.
 This product can be operated by both men and women.
OBJECTIVES:
 To design and fabrication of Pedal operated flour mill.
 To obtain fine flour of grains and pulses.
 To have good health by exercise of cycling.
 The device can be operated by both men and women.
 This can be operated at any time.

CHAPTER-1
INTRODUCTION
India is the second most populous country in the world. With on growing
population the needs of people and their usage is also growing, in such cases demand of
electricity is very high here. Biomass and other non –commercial fuels constitute around
40% of energy requirements in India. Around 85.49% of the Indian villages are
electrified, but many of the remote villages are still without electricity. People in villages
mainly use bicycle as their means of transport for small distances, in such places our
system is of great use.
The use of fossil fuels and other non-reusable sources of energy must be reduced
in order to keep emissions low and alleviate the use of diminishing resources. Humans
are able to generate around 100 watts of power while bicycle riding. However this power
is wasting without our knowledge, but if we make use of this we can able to get some
energy. The idea of human powered generation has been implemented in many different
situations. Some examples include hand-crank radios, shaking flashlights, and receiving
power from gym equipment. The use of exercise equipment for a clean source of energy
would turn out to be an even more fun experience for participants, it would provide them
a means to exercise while indirectly flouring the grains.
The pedal operated flourmill utilizes human energy to produce fine flour quickly
and efficiently. The goal is to provide technological solution to problem in the rural world
by using detailed opportunity recognition, evaluation, and development of prototype. The
prototypes are then turned over to the developing world for manufacturing, distribution
and use. Some applications include pedal powered laptops, pedal powered electricity and
pedal powered water wells. Some third world development projects currently transform
used bicycles into pedal powered tools for sustainable development.
Using human operated flourmill gives a power source that is not directly derived
from natural sources. An example is that a human operated flour mill can be operated if
there is no sun for solar generation, no wind for wind generation, and no water for hydro
generation. The flour mill from pedal is perfect for remote areas, hilly regions, strategic
location, Islands etc.
It is important to visualize new ways to bring non-renewable resource to the
people as population continues to grow and power shortages continue to occur. Much of
the power that is provided to people today is done in very un-sustainable ways; new ideas
are needed to transit into a post cheap-petroleum era. This design relates to very compact

and easily portable flourmill unit, which besides being used as a flour extractor can also
be used as cycle exerciser. It serves dual purpose of fine flour extractor and helping the
person to maintain physical fitness through exercise of muscles of legs. It can be pedalled
or cranked by hand/foot.
In order to make it possible to operate the system effectively and efficiently it is
necessary to develop this system by giving due respect to human limitation. Hence
ergonomic system of pedal operated flour mill is developed. The ergonomic consideration
mainly includes the selection of components of system which suits the human capability
and develops the posture to operate system to reduce the fatigue and chances of
musceletole disorders.
1.1 History of flour mill
Beginning in 1880 and for 50 years thereafter, Minneapolis was known as the
“Flour Milling Capital of the World” and more informally, as the “Mill City. The city
grew up around the mills. In 1870, the city’s population was 13,000. Twenty years later,
it had grown to nearly 165,000.Grain came in via rail lines that stretched across the
Northern Plains grain belt into the Dakotas and Canada. Trains also carried the milled
flour to Duluth and to eastern U.S. destinations both for export and domestic distribution.
After World War I, the milling industry in Minneapolis began to decline. As the
industry moved out of Minneapolis, the old mills fell into disuse. The Washburn A Mill
closed in 1965 and was nearly destroyed by fire in 1991. Its ruins were incorporated into
the Mill City Museum.
Fig.1.1: Historic photos of minneapolis mills

1.1.1 Conventional stone flour mill
Conventional flour mill which gives the flour used in olden days. It is operated by
human effort only, this flour mill consist of same sized two round shaped stones one is
fixed another one is rotated by hand. Stone milling was the norm throughout history until
around the 19th century. As times and cooking practices changed, it was found that stone
milling didn’t produce flour that was fine enough for making pastries.
Stone milling also produces a nutty flavour and texture that consumers were
finding less than ideal for some of their recipes. Millstones also wear down after use, and
have to be “dressed” or sharpened about every 90 days or so, creating concern that
corundum dust from the grinding stones became part of the flour being produced.
Fig.1.2: Conventional stone flour mill
1.1.2 Electrical Stone Flour mill
Electric stone flour mill is as well as traditional stone flour mill, the flour contains
mineral elements through the grinding stone milling. And it also reserves the traditional stone
flour mill merits such as low speed, low speed grinding and low temperature processing, these
characteristics guarantee the vitamin and trace element not damaged by high temperature, rich
nutrition in flour.
Electric stone flour mill is easy to operate, it is automatic feeding, automatic separation
that can just operate by one person. It saves a lot of manpower and material resources in
production. Besides, it can also be used to grind the beans, grains, etc.

Fig.1.3: Electrical stone flour mill
Grinding roller of electric stone flour mill is made of stainless steel, it is clean, healthful, flour
feeding and discharge are convenient, especially suitable for small flour mill factory and
home use.
Fig.1.4: Electrical flour mill
1.2 Rollermills
Roller mills are mills that use cylindrical rollers, either in opposing pairs or
against flat plates to crush or grind various materials such as grain, ore, gravel, plastic
and others. Roller grain mills are an alternative to traditional millstone arrangements
in gristmills. Roller mills for rock complement other types of mills, such as ball mills
and hammer mills in such industries as the mining and processing of ore and
construction aggregate, cement milling and recycling.

1.2.1 Types of Mills
Two-roller mills
Two-roller mills are the simplest variety, in which the material is crushed between
two rollers before it continues on to its final destination. The spacing between these two
rollers can be adjusted by the operator. Thinner spacing usually leads to that material
being crushed into smaller pieces.
Fig.1.5: Two-roller mill
Four-roller mills
Four-roller mills have two sets of rollers. When using a four-roller mill to mill
grain, the grain first goes through rollers with a rather wide gap, which separates the seed
from the husk without much damage to the husk but leaves large grits. Flour is sieved out
of the cracked grain and then the coarse grist and husks are sent through the second set of
rollers which further crush the grist without damaging the crusts. Similarly, there are
three-roller mills in which one of the rollers is used twice.
Fig.1.6: Four-roller mills

Five- and Six-roller mills
Six-roller mills have three sets of rollers. When using this type of mill on grain,
the first set of rollers crush the whole kernel, and its output is divided three ways. Flour
immediately is sent out the mill, grits without a husk precede to the last roller, and husk,
possibly still containing parts of the seed, go to the second set of rollers. From the second
roller flour is directly output, as are husks and any possible seed still in them and the husk
free grits are channeled into the last roller. Five-roller mills are six-roller mills in which
one of the rollers performs double-duty.
Fig.1.7: Five-flour mill
1.3 Bicycle
A bicycle, often called a bike or cycle, is a human-powered, pedal-driven, single-track
vehicle, having two wheels attached to a frame, one behind the other. A bicycle rider is
called a cyclist, or bicyclist.
The basic shape and configuration of a typical upright or "safety bicycle", has changed
little since the first chain-driven model was developed around 1885. But many details
have been improved, especially since the advent of modern materials and computer-aided
design. These have allowed for a proliferation of specialized designs for many types of
cycling.

The great majority of today's bicycles have a frame with upright seating that looks
much like the first chain-driven bike. These upright bicycles almost always feature the
diamond frame, a truss consisting of two triangles, the front triangle and the rear triangle.
The front triangle consists of the head tube, top tube, down tube, and seat tube. The head
tube contains the headset, the set of bearings that allows the fork to turn smoothly for
steering and balance. The top tube connects the head tube to the seat tube at the top, and
the down tube connects the head tube to the bottom bracket. The rear triangle consists of
the seat tube and paired chain stays and seat stays. The chain stays run parallel to the
chain, connecting the bottom bracket to the rear dropout, where the axle for the rear wheel
is held. The seat stays connect the top of the seat tube to the rear fork ends.
The drive train begins with pedals which rotate the cranks, which are held in axis by
the bottom bracket. Most bicycles use a chain to transmit power to the rear wheel. A very
small number of bicycles use a shaft drive to transmit power or special belts. Hydraulic
bicycle transmissions have been built, but they are currently inefficient and complex.
Since cyclist’s legs are most efficient over a narrow range of pedalling speeds a
variable gear ratio helps a cyclist to maintain an optimum pedalling speed while covering
varied terrain. Some mainly utility bicycles use hub gears with between 3 and 14 ratios,
but most use the generally more efficient derailleur system by which the chain is moved
between different cogs called chain rings and sprockets in order to select a ratio. A
derailleur system normally has two derailleur one at the front to select the chain ring and
another at the back to select the sprocket.
Fig.1.8: Bicycle

Conceptual Diagram

 Power is applied by means of cycling through chain than rear wheel start rotates.
 Rear wheel is connected in series to smaller wheel through Open belt drive.
 One end of shaft is connected to smaller wheel and other end to the rollers of mill.
 Rollers are designed such that clearance can be made prior to type of grain and
fineness required to flour.
 Mill consists of Hopper which stores and feed the grains and pulses to rollers.
 The fine flour is collected at the bottom when it is passed between the rollers.

CHAPTER-2
DESIGN CALCULATION
Generally, the design of this system depends primarily on the Flour mill input power.
The input power to be produced affects the dimensioning as well as the input parameters
like torque, speed, etc. In light of the above constraints, the following design
considerations and assumptions have been made for this project design.
1. Sizing and economic considerations:
This system is design to compact in consideration of the power
requirement as well as reduction in the cost of fabrication. For affordability, the
device is relatively small.
2. Safety Considerations:
This system is design in such a way that women and children can use it for
sustained period of time. It preserves the safety of our immediate environment
from noise and air pollution because it’s noiseless and smokeless. Stability of the
unit was also considered to ensure that the equipment remains upright at all time,
i.e. it should not drift or bend to one direction and it should remain stationary.
3. Ergonomics:
The ergonomics aspect has to do with optimizing the physical contact
between human and the equipment. Four important areas of bike ergonomics are
usually considered:
• The strain of the arm and shoulder
• The muscle support and the position of the lower back
• The work of proper pedalling
• The crank length
4. Technological consideration:
The design of this system is well considered in such a manner that it can
be produced within the technology of our immediate environment.

I. PedalPower
Torque = Force*perpendicular distance (Assume Pedal length = 170 mm)
= 7*9.81*170
T = 11673.9 N-mm
Power =
2𝜋NT
60
=
2∗𝜋∗50∗11673.9
60 ∗1000
(Assume pedal/rpm = 50)
= 61.124 Watt
P = 0.08193 HP
II. First Stage GearSystem( Sprocketdesign)
 The first stage gear system comprised of the input pedal system and the output
sprocket.
 The gear system made up of a driver toothed gear = 44 teeth
 The driven gear with = 18 teeth
 The two gears are linked with a chain.
 Angular speed =
Ɵ
Time
=
Final angle −Initial angle
Time
We know,
WA
WB
=
RB
RA
=
NB
NA
=
DB
DA
Where,
WA,B = Angular speed of sprocket a and b respectively.
RA,B = Radius of sprocket a and b respectively.
NA,B = Number of teeth A and B respectively.
DA,B = Diameter of sprocket a and b respectively.
To find rpm of the sprocket,
WA
WB
=
NB
NA
WA = WB*
NB
NA
Let us assume, WA =
Ɵ
𝑡
Where,
Ɵ = wheel rotates through
WA =
6.28
8
= 0.785 rad/sec

WA = 47.1 rpm
WB = WA*
NA
NB
= 0.785*
44
18
= 1.92 rad/sec
WB = 115.13 rpm
* The pitch P of a gear which is distance between equivalent points on neighbouring teeth
along the pitch circle.
Driver gear,
PA =
2πRA
NA
=
2∗π∗170
44∗2
PA = 12.138 mm
Driven gear,
PB =
2πRB
NB
=
2∗π∗56
18 ∗2
PB = 9.77 mm
Speed ratio,
SR =
NA
NB
=
44
12
SR = 2.44
III. SecondStage GearSystem( Pulley design )
The second stage gear system is composed with pulleys of different diameter.
To get the speed of the flywheel, since the smaller sprocket in the first stage and
the flywheel form a compound gear arrangement, they rotate at same speed that is,
WB = WC =115.13 rpm
WC
WD
=
DD
DC
WD = WC*
Dc
DD
= 1.92*
560
300
= 3.584 rad/sec
WD = 215.04 rpm

IV. Designof V-Belt
There are lots of factors to be considered when selecting the type of belt to
be used.
• The speed of the driving or driven pulley
• The power to be transmitted;
• The centre distance between pulleys
• Speed ratio
• Service condition
1. Selection of belt cross section.
Equivalent pitch diameter of smaller pulley,
de = dpFb ……………. 21.35(DDHB, Lingaya vol-2)
Where,
dp = d1 = 300 mm
Fb = smaller diameter factor ……………. Table 21.25
Fb = 1.13 for speed ratio =
n2
n1
=
215
115
= 1.87
de = 300*1.13
= 339 mm
Based on ‘de’ selecting the c/s of belt ……………. From pg.no. 21.13
‘C’ cross-section
2. Velocity
V =
𝜋𝑑1𝑛1
60,000
=
𝜋∗300 ∗215
60,000
= 3.37 m/sec
3. Power capacity
Based on the cross-section selected, calculating power capacity N*
N* = 𝑉 (
1.47
V0.99 −
143.27
de
−
2.34 V2
104 ) ………… 21.32 (DDHB)
= 3.37(
560
3.370.09 −
143 .27
339
−
2.34∗3.372
104 )

N* = 3 KW
4. Number of v-belts,
I =
NFa
N∗FcFd
……………….21.36 (DDHB)
Where
N = Total power transmitted in KW
N* = Power capacity
Fa = service factor ……………… From table 21.28
We know,
i = 1 (To Find N=?)
Re arrange 21.36
N =
i∗N∗
FcFd
Fa
Fa = 1.2
If the condition is not given then assume medium duty and 10-16hrs duty/day.
Pitch length, L = 2C+
π
2
(D+d)+
(D−d)2
4C
……………….. 21.38
The centre distance is not given
Cmax = 2(D+d) ………….. 21.39 (DDHB)
= 2(300+560)
= 1720 mm
Cmin = 0.55(D+d)+T ……………. 21.40 (DDHB)
For ‘T’ from the table 21.23 for the selected cross-section
Top width, W = 22 mm
Thickness, T = 14 mm
Cmin = 0.55(560+300)+14
= 487 mm
Assuming C = 500 mm
L = 2*500+
π
2
(560+300)+
(560−300)2
4∗500
= 2384.68 mm
From the table 21.29 nearest standard value of nominal pitch length for the
selected ‘C’ cross-section belt, L= 2342 mm

Nominal inside length = 2286 mm
Now from the table 22.27 for nominal inside length = 2286 mm, and ‘C’ cross-
section belt,
Correction factor for length, Fc = 0.91
Angle of contact, 𝜃 = 2cos−1
(
D−d
2C
) …………….. 21.45(DDHB)
= 2cos−1
(
560 −300
2∗500
) = 149.85°
From table 22.26 when 𝜃 = 149.85°
Correction factor for angle of contact
Fd = 0.83 (v-belt)
N =
1∗3∗0.91∗0.83
1.2
N = 1.88 KW (Total Power Transmitted)
5. Correct Centre distance,
C =
L
4
-
𝜋( 𝐷+𝑑)
8
+√{
L
4
−
π( 𝐷+𝑑)
8
}
2
−
( 𝐷−𝑑)2
9
=
2286
4
-
𝜋(560+300)
8
+√{
2286
4
−
π(560 +300)
8
}
2
−
(560−300)2
9
C = 448.72 mm
6. Specification of v-belt,
The v-belt selected is,’C’ ………………….. 22.86
W = 22 mm
T = 14 mm ………………. Table 21.23
W
T
V. Designof RollerChain
Let,
P = Pitch
d1 = Diameter of smaller sprocket

d2 = Diameter of larger sprocket
n1 = Speed of smaller sprocket
n2 = Speed of larger sprocket
z1 = Number of teeth on smaller sprocket
z2 = Number of teeth on larger sprocket
L = Length of chain
Lp = Length of chain in pitch
C = Centre diameter
Cp = Centre distance in pitches
Fu = Ultimate or break load
Fo = Required chain pull
Fa = Allowable pull
Ao = Working factor of safety
Aa = Actual factor of safety
V = Velocity
Chain drive selection
In order to select a chain drive the following essential information must be known,
 The power to be transmitted.
 The speed of the driving and driven pulleys.
Pitch of chain,
P =
2π(R+r)
T1+T2
=
2π(85+28)
44+18
P = 11.452 mm
Centre distance,
X =
170+56
2
+ 30 = 143 mm
Length of chain,
L =
11.452
2
(44 + 18) + 2 ∗ 143 +
(
11.452
2
csc
180
44
+
11.452
2
csc
180
80
)
143
= 355.012+286+
5.711+5.64
143
= 355.012+2.86+0.079
L = 641.091 mm

VI. Frame Design
1. Choosing Frame Material
One of the key elements of the design process of objects under cyclical
changing loading is the knowledge of service load history. It is especially
important in the case of the bike exerciser in which components are under threat
of fatigue damage formation because of the diversified influence of many factors
of deterministic and random nature. Bike frames encounter a complex set of
stresses which in most cases cannot be calculated by hand. Therefore, in designing
a frame, engineers usually makes use of an older design which has proven reliable
as a starting point.
The frame of the POPG was designed to replicate a typical Schwinn DX
bike exerciser with little modifications on the materials used in order to minimize
cost and also considering availability of materials. The materials used for exercise
bike frames have a wide range of mechanical properties. For most bike builders,
steel is the material of choice; steel bikes impart a certain level of confidence in
the ability of the bike. It provides the ideal combination of performance and
purchase cost. They can be inexpensively repaired and have the ability to reveal
frame stress injuries before they become failures. When a steel frame breaks, it
tends to break slowly rather than suddenly and they have the ability to store and
release energy at different degrees of the pedal strokes.
2. Frame Dimensions
To ensure the safety of the user and promote efficient cycling, the
dimensions of the bike and cyclist must be taken into account, along with the
amount of lateral and vertical clearance needed, in the planning and design of
bicycle facilities. The dimensions of a typical bicycle are a handlebar height of
0.75 - 1.10 m (2.5 - 3.5 ft.), handlebar width of 0.61 m (2 ft.), and bicycle length
of 1.5 - 1.8 m (5 - 6 ft.). They often provide little traction. The general
dimensions adopted for the design was (1200 x 200 x 860) mm (Mn/DOT, 2007).
VII. FlywheelDesign
Flywheels are designed to store and release kinetic energy. A Flywheel is disc-
shaped, and true to its weight on all sides and locations of the disk. The flywheel is
designed to provide a more steady flow of momentum. The size and weight of the
flywheel will determine the amount of energy that can be produced from peddling the
bike. The mechanical advantages of using a flywheel is that its energy output is consistent

and, depending on the size of the flywheel, it is able to store and release great amounts of
energy even after the peddling has ceased. The kinetic energy stored in the flywheel is
given as.
K.E =1/2*I*w
Where
I = polar moment of inertia
w = angular velocity of the flywheel
Two types of flywheel are available:
Heavy and light flywheel,
• A heavy flywheel will take much more effort to get started but will be able to
provide the steadiest flow of energy once the heavy weighted disk is in motion. The
disadvantage in using a heavy flywheel to power a mechanical device is the individual
peddling the bicycle would also have a hard time getting the wheel’s momentum engaged
and would require more energy input than is required.
• A light flywheel will be easy to engage through peddling power. The amount of
momentum is not as great as a heavier flywheel but will be sufficient enough to rotate the
pulley of the DC permanent magnet without causing much stress on the individual. A
flywheel weighing about 25 - 35 pounds is light enough for an individual to mechanically
power. In the light of the above, the light flywheel scored higher than the heavy flywheel.
Because the aesthetics of the drive is not crucial to the appearance of the design project in
general, the use of the light flywheel for the final design is chosen over the use of the
heavy flywheel.
VIII. Bearing Selection
Bearing dimensions have been standardized on an international basis. The
dimensions are a function of the bearing bore and the series of bearing: Extra light (100);
Light (200); Medium (300); Heavy (400). In order to select the correct bearing for the
design, the basic dynamic radial load was calculated, multiply by the service factor. The
bearing is then selected from the basic static and dynamic capacity table (Khurmu and
Gupta, 2010). The mathematical relationship for the bearing selection is presented below:
Service life
𝐿𝐻 = 𝑌𝑒𝑎𝑟𝑠 ∗ 1𝑑𝑎𝑦 ∗ ℎ𝑟𝑠/𝑑𝑎𝑦
Life of bearing in revolutions
𝐿 = 60 ∗ 𝑠𝑝𝑒𝑒𝑑 ∗ 𝐿𝐻

The following considerations are of importance in bearing design: Finish precision of
bearing shaft, fillet radii of corners of shaft and the height of shoulder.
Table 1: Bearing Selection
Bearing No. Bore (mm) Outside diameter(mm) Width
205 25 52 15

REFERENCES
[1]. Mr.Prasad A Hatwalne et.al“An Ergonomic Design Of Pedal Operated Flour
Mill” International Journal of Scientific and Research Publications, Volume 2, Issue
4, April 2012 ,ISSN 2250-3153.
[2]. Prasad A.Hatwalne et.al, “Design and development of Pedal operated flour
mill” New York Science Journal, 2011, 4(5).
[3]. Carlos Marroquin et.al. “Pedal Powered Mill” Design & Realisation by Carlos
Marroquin Instructions by Henry Godfrey Produced by Maya Pedal, 2010 Version
1.0.
[4]. Amos Waweru.“Design Of A Bicycle Peddle Operated Grain Mill” Jomo
Kenyatta University of Agriculture and Technology, 2009.
[5]. Dhanasegaran A et.al.“Design and Fabrication of Pedal Powered Circular Saw
for Wood Working Applications” International Journal of Current Engineering and
Technology, Vol.6, No.2, April 2016.
[6]. B.Sneha et.al. “Generation of Power from Bicycle Pedal” International Journal
of Advanced Research in Electrical, Electronics and Instrumentation Engineering,
Vol. 4, Issue 10, October 2015.
[7]. Dhanasegaran A et.al. “Design and Fabrication of Pedal Powered Circular Saw
for Wood Working Applications” International Journal of Current Engineering and
Technology, Vol.6, No.2, April 2016.
[8]. Sanjay N.Havaldar et.al. “Pedal Operated Water Filtration System”
International Journal of Current Engineering and Technology, 2016.

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Design and Fabrication of Pedal operated Flour Mill