Final Report Edited

Design of mechanical driven reaper Farm technology
ABSTRACT
This report deals with the brief design analysis, design concept, design matrix,
performance, literature review, manufacturing process, assembling process,
detailed drawing and assembly drawing of the mechanical driven reciprocating
reaper which reaps or harvests 1.8 hectare per day on doing 8 hours
By Alemu Yamane Mechanical engg dept. 0

alemuyem2007@yahoo.com
1. BACK GROUND AND JUSTIFICATION

1.1 Scio economic conditions of Ethiopia
Agriculture is an endeavor practiced in all countries. From the earliest times,

humankind has engaged in some form of planting, herding, or gathering. Also
Ethiopia has great agricultural potential because of its vast areas of fertile land,
diverse climate, generally adequate rainfall, and large labor pool. Despite this
potential, however, Ethiopian agriculture has remained underdeveloped. Because
of drought, which has persistently affected the country since the early 1970s [1]),
a poor economic base, low productivity, weak infrastructure, and low level of
technology. But still now the estimated 85% [2] of the population is engaged in
agriculture and agricultural production.
1.2 Mechanical driven reaper
Mechanical driven reapers are harvesting-machines used for cutting grain-crops.

It consists of the following parts
The structure or body which carries or holds all the parts of the machine
The transmission part contains the transmission of the power or movement

from the wheel to the reciprocating blades and the revolving reel through belt
and gears.
Cutter blade is the main part that attains its name to be the harvester or reaper.
Wheel or axel with its shaft to create the motion or rotation to drive all
mechanisms.
The upper shaft is an intermediate shaft to transmit power and motion from the
wheel or axel shaft to the recovery reel and cutter blade.
Belts are used to transmit power from the axel to the intermediate shaft (V-
belts) and from the intermediate shaft to the recovery reel (flat belt) and to drive
the canvas or the conveyor (timing belt).

Canvas is used to transmit or convey the harvested or cut grain to the free
space side.
Revolving reel swept the harvested grain to the face of the conveyor by
revolving on its axis.
Reciprocating mechanism is used to convert the rotation speed of the inclined

shaft to the linear motion or side way movement of the cutter blades.
Inclined shaft carries and drives the canvas and transmit power from the
intermediate shaft to the cutter blades using bevel gears.

2. INTRODUCTION
2.1 Farm mechanization
Agricultural mechanization helps in increasing production, productivity and

profitability in agriculture by achieving timeliness in farm operations, bringing
precision in metering and placement of inputs, reducing available input losses,
increasing utilization efficiency of costly inputs (seed, chemical, fertilizer,
irrigation, water etc.), reducing unit cost of produce, enhancing profitability and
competitiveness in the cost of operation. It also helps in the conservation of the
produce and byproducts from qualitative and quantitative damages; enables
value addition and establishment of agro processing enterprises for additional
income and employment generation from farm produce.
2.2 Simple Harvesting machineries and tools
2.2.1 Sickle
A sickle is a curved, hand-held agricultural tool typically used for harvesting
grain crops before the advent of modern harvesting machinery. It consists of a
curved blade with a short, one-hand handle attached. The inside of the curve is
sharp, so that the user can swing the blade against the base of the crop, catching
it in the curve and slicing it at the same time. It is sometimes referred to as a
'grass hook'.
2.2.2 Scythe
Scythe is a similar tool with the sickle used to harvest grain crops. The most
noticeable difference between a sickle and the scythe is the shape of the blade of
which the Scythe blade is more linear whereas a sickle blade is more in the shape
of a C with a point at the top.
2.2.3 Cradle
Cradle is a more developed tool for reaping and harvesting. It consists of an
arrangement of fingers attached by a light frame work to the snatch of a scythe.
Its purpose is to gather the straw as it is cut and deposit it in a swath. At the end
of the cutting stroke, the cradle is tilted to drop the straw in a pile. Also,
substantially more grain can be cut in a day with the cradle. However, loss due to
shattering (grain dislodged from heads due to shock) is greater with the cradle
which makes to continue using the sickle to harvest grain.
Fig.1 harvesting man using cradle [3]
2.2.4 Mowers
An agricultural mower having a crop cutting rotor that is rotatable about an
upright axis and cuts a strip of crop along a cut edge of the crop so as to emerge
laterally from side cut edge, and a crop guide that is located adjacent the
periphery of the rotor where it emerges from side cut edge of the crop so as to
support the crop upright at side edge while it is cut. The guide thereby avoids
leaving any uncut lines of crop caused by the rotor pushing crop aside at a cut
edge in the crop where it is unsupported by adjacent standing crop. The
invention is particularly applicable to a mower with two or more cutting rotors
that are rotatable in the same sense about respective upright axes alongside one
another with one rotor offset rearwards relative to the other so as to cut crop
adjacent a cut edge left by said other rotor, the crop guide being located adjacent
the periphery of said one rotor to support the crop along said edge.
2.2.5 Reapers
Reapers are harvesting-machines used for cutting grain-crops. They either
deliver the grain to one side in gavels ready to bind into sheaves, or elevate the
gavels upon a platform where two operators bind them into sheaves by hand. An
attachment is often provided whereby the machine successfully performs the
binding of the sheaves automatically with wire before delivering them
The essential parts of a reaper are: the cutting arrangement, similar in design to
that of mowing-machines (except that in many cases sickle-knives in place of
plain knives are used); sweep or table rakes to convey the grain to and from the
machine; and mechanical means to regulate the delivery of the gavels, so that the
size of the same shall be sufficient for binding even in spots or places upon the
land where the crop is very light. Many of these machines are constructed so that
the various devices for raking, sweeping, gathering, or delivering, may be
detached, leaving the machine a simple mower

3. OBJECTIVES OF THE PROJECT
Objective of this project is investigating, acquiring, designing and implementing

of simple farm machine, mechanical or manual driven reapers with a reasonable
cost for our farmers to an end of the tedious handiwork, the harvesting using
sickle, develop or to increase their income by minimizing harvesting cost, their
time and number of workers that participating during harvesting season.

4. LITERATURE REVIEW
4.1 Agricultural machineries
Agricultural machinery is designed to till the soil and render it more suitable
for crop growth, to sow seeds, to apply agricultural chemicals for improved
plant growth and control of pests and diseases, and to harvest and store the
mature crops. There is an extremely wide variety of agricultural machines, but
all are essentially a combination of gears, shafts, chains, belts, knives, shakers
and so on, assembled to perform a certain task. These parts are usually
suspended in a frame which may be either stationary or, as is more often the
case, mobile and designed to perform the desired operation while moving
across a field. The major groups of agricultural machines are: soil tillage
machines; planting machines; cultivating machines; forage harvesting
machines; grain, fiber, vegetable, and fruit and nut harvesting machines;
agricultural chemical applicators; transport and elevating machines; and sorting
and packaging machines.
Farming in Ethiopia is also, generally labor intensive. However, in some

localities of Arsi (Asasa, Etheya, Lole, and Dhera) there has been a shift towards
the use of agricultural machinery, especially for wheat production since the
inception of the Chilalo Agricultural Development Unit (CADU) in 1969.[4]
Farmers in the aforementioned areas have been interested in mechanical
harvesting due:
To the initial promotion of agricultural machinery
CADUs research section evaluated the performance of local farm

implements against new farm
Machines various models of harvesting and threshing machines were

evaluated, and a substantial output loss resulting from traditional harvesting and
threshing techniques was Found.

Technical feasibility and economic viability of the new methods were

confirmed.
The main consequences of introducing mechanical technologies during the

1970s[5] were the eviction of Tenants, increased unemployment, and soil erosion
4.1.1 Soil tillage machines

These include ploughs, tillers, subsoiler, harrows, rollers, levelers, graders and
so on. They are designed to turn, agitate, level and compact the soil to prepare
it for planting. They may be small in size and require only a small power
source (as in the case of a one-person roto-tiller for tilling a rice paddy), or
they may be large and require a considerable power source (as in the case of a
combined subsoiler, drill and harrow).
Fig.2 Goldoni Secondary Tillage Machines [6]
One of the stands out benefits of walking tractors is their use as secondary tillage
machines. Their low weight minimizes compaction while their maneuverability
encourages their frequent use to keep weed competition down from early crop
emergence or soon after transplanting. The addition of an inter row tiller
attachment speeds up your field, breaks up encrusted and incorporate
amendments.

Fig.3 Goldoni Grain Drill [7]
Combine a accurate metering grain drill with your walking tractor and place your
grain seed or cover crop where it will flourish, do away with the hit or miss
results of broadcast seeding. Choose disc openers for heavier ground and areas
less well prepared. Or choose shoe type openers in lighter soils and those that
have been well tilled.
4.1.2 Planting machines

These include planters, drills, broadcast seeders and so on and are designed to
take seeds from a hopper or bin and insert them in the soil at a predetermined
depth and spacing or spread them uniformly over the ground. Planters may be
of simple design and comprise a single-row seeding mechanism, or they may
be highly complex (as is the case with the multi-row planter with attachments
that simultaneously add fertilizer, pesticides and herbicides).
Fig.4 direct planting machine [8]

This planting machine is made for use in small and medium-sized tractors;
available from 1 to 7[8] lines; hydraulic planting machine, articulated, with
pantograph system for direct planting; the lightest planting machine in the
market; seed container capacity: 18 Kg; fertilizer container capacity: 60Kg;
estimated weight (empty) 110 KG per line[8].
Individual articulated system, to the right or to the left, to make planting in
curves and slopes easier for planting soy beans, black beans, corn, sunflower
seeds, and other grains.
4.1.3 Cultivating machines

These include rotary hoes, cultivators, weeders (mechanical and flame) and so
on. They are used to eradicate undesirable weeds or grasses which compete
with the plant for soil moisture and make the harvest of the crop more difficult.

They also improve the soil tillage so as to make it more absorptive of rain.
Fig.5 cultivating machine [9]
Fig.6 A farmer tilling around a plum tree with a cultivating machine [10]

This machine is for weeding and aerating the soil. We suggested weeding near
the trees by hand to avoid harming the tree's roots. The trees further toward the
rear are peach trees.
Fig.7 garden rake [11]
Rakes with short, stiff spikes are normally used for raking hay, fallen branches,
seaweed and paper-waste. The functionally designed Universal Rake with wings
can also be used for cultivating. The wings support the spikes and keep them
from digging into the ground. The wings are removable. The open structure
allows soil to flow through the rake's head, which also makes cultivating work
easier.
4.1.4 Forage harvesting machines

These include mowers, choppers, and balers and so on and are designed to sever
the stems of roughage crops from their roots and prepare them for storage or
immediate use. The machines also vary in their complexity: the simple mower
merely cuts the crop, whereas the chopper will not only separate the stalk from
the root but will also chop the entire plant into small pieces and load it into a

vehicle, which may be a towed wagon. Crimpers, which crush or break the stems
of plants, are often used to expedite the field-drying process of fodder crops to
prevent spoilage, especially of legumes that will be placed in dry storage or
baled. Pelleting machines are used to compress fodder crops into compact cubes
for mechanical feeding of livestock. Balers are used to compress fodder into
square or round bales to facilitate storage and handling. Some bales are small
enough to handle manually, while others may be so large as to require
mechanical handling systems [12].
4.1.5 Grain and fiber harvesting machines

These include reapers, binders, corn pickers, combines, threshers and so on.
They are used to remove the ripe grain or fiber from the plant and place it in a
bin or bag for transport to the storage area. Grain harvesting may involve the
use of a number of machines, such as a reaper or binder to cut the standing
grain, a wagon or truck to transport the crop to the threshing or separating
machines and vehicles to transport the grain to a storage area. In other cases
many of these functions may be performed by a single machine, the combine
harvester (fig.8), which cuts the standing grain, separates it from the stalk,
cleans it and collects it in a bin, all while moving through the field. Such
machines will also load the grain into transport vehicles. Some machines such
as cotton pickers and corn pickers may operate selectively and remove only the
grain or fiber boll from the stem or stalk.

Fig.8 Combine for harvesting wheat without an enclosed cabin [13]
4.1.6 Vegetable harvesting machines

These include diggers and lifters, and are designed either to dig the crops from
the earth and separate them from the soil or to lift or pull the plant free. The
potato digger, for example, may form part of a potato combine comprising a
sorting, grading device, polisher, bagger and elevator. At the other extreme is the
simple two-wheeled, bladed sugar-beet lifter which is followed by hand laborers.
4.1.7 Fruit and nut harvesting machines

These machines are used to harvest berries, fruit and nuts. They may be as
simple as a tractor-mounted, vibrating tree shaker which separates the ripe fruit
from the tree. Or they may be as complex as the ones which harvest the fruit,
catch the falling fruit, place it in a storage container and later transfer it to
transport vehicles.
4.1.8 Transport and elevating machines

These also vary considerably in size and complexity ranging, for example,
from a simple wagon comprising merely a platform on wheels to a self-loading

and stacking transport unit. Inclined chain, flight or belt conveyors or other
mechanical handling devices are used to move bulky material (hay, straw, ear
corn and so on) from wagon to storage or from one location in a building to
another. Screw conveyors are used to move granular material and grain from
one level to another, and blowers or pneumatic conveyors are used to move
light materials horizontally or vertically.
Fig.9 Fort Powered Trailers [14]
4.1.9 Agricultural chemical applicators

These are used to apply fertilizers to stimulate plant growth or herbicides and
pesticides to control weeds and pests. The chemicals may be liquid, powdered
or granular, and the applicator distributes them either by pressure through a
nozzle or by centrifugal force. Applicators may be portable or vehicle-
mounted; the use of aircraft for chemical application is growing rapidly.

4.1.10 Sorting and packaging machines

These machines are usually stationary. They may be as simple as a fanning
mill, which grades and cleans grain merely by passing it over a series of
screens, or as complex as a seed mill, which will not only grade and clean but
also, for example, separate different types of seeds. Packaging machines
usually form part of a sophisticated grading system. They are used primarily
for fruit and vegetables and may wrap the produce in paper, bag it or insert it
into a plastic container.
4.1.11 Power plants

Electric motors may be used to drive stationary equipment permanently
located near a mains supply; however, since many agricultural machines are
mobile and must operate in remote areas, they are usually powered by an
integral petrol engine or by a separate engine such as that of a tractor. Power
from a tractor may be transmitted to the machine via belt, chain, gear or shaft
drives; most tractors are fitted with a power take-off coupling specially
designed for this purpose.

4.2 Grain Harvesting and reapers [15]
Reaper is any farm machine that cuts grain. Early reapers simply cut the crop
and dropped it unbound, but modern machines include harvesters, combines, and
binders, which also perform other harvesting operations.
4.2.1 "Reaping Hook" or Sickle
With the sickle or reaping hook one man could cut from one-half to one acre in a
hard day's work. The cut grain was later bound by hand.
Fig.10 Reaping Hook [15]
4.2.2 Cradle
The cradle was the most efficient means of cutting grain before McCormick's
invention of the reaper. The cradle consisted of a broad scythe with a light frame
of four wood fingers attached to it. The advantage of the cradle was that by a
turn to the left the operator could throw the grain into a swath, ready to be raked
and bound into sheaves. This improvement was introduced in America about
1776[15], according to Professor Brewer of Yale, and was the common
instrument of grain harvesting as late as 1840. For cradling grain, two acres was
considered a day's work.
Fig.11 The Cradle [15]

4.2.3 Scythe
The scythe was the companion tool to the reaping hook or sickle. It was always
used for mowing grass but sometimes oats and barley were cut with it. It was not
generally used for cutting wheat. With the scythe a man could cut up to three
acres a day.
Fig.12 The Scythe [15]
4.2.4 McCormick reaper

This McCormick reaper of 1831[15] shows the wide master wheel which carried
most of the weight of the machine and, through ground transaction, supplied
power to operate the reel and the reciprocal knife. The world's first reaper
incorporated seven basic principles (listed above) which have ever since been
found essential in virtually all grain-cutting machines.
While this first machine required only 2 people for operation (a person to ride
the horse and a man to rake the cut grain from the platform), it cut as much grain
in one day as 4-5 men with cradles or 12-16 men with reaping hooks.
Fig.13 the World's First Reaper [15]
The McCormick Patent Reaping Machine of 1857 [15] combined machinery for
reaping and mowing, and was built from 1852-1865[15]. Its chief improvements
over the 1831 reaper were seats for driver and raker, a cutting knife fabricated in
sections rather than one piece, and an all-metal main wheel. This machine also
cut a wider swath than the first reaper and was pulled by two horses.
Fig.14 McCormicks Patent Reaping Machine [15]
The McCormick Patent Reaping and Mowing Machine were manufactured from
1852-1865, with various improvements being incorporated from time to time.
This specific machine includes seats for raker and driver and cut a wider swath
than McCormick's reaper of 1831.
Fig.15 McCormick's Patent Reaping and Mowing Machine [15]
The McCormick Automatic Self-Rake Reaper was originally patented in 1858

and was manufactured and sold in large numbers from 1862 until about 1875
(when it was replaced by a more efficient machine bought out by McCormick).
The harvester, known as McCormick's "Old Reliable," was a one-man machine
which released yet another person to aid in other harvest jobs. Its automatic rake

swept cut grain off the platform, depositing the grain in neat gavels on the
ground, ready to be bound into bundles by the hand binders.
Here an "Old Reliable" of 1864[15] deposits neat gavels of grain on the ground
to be bound by a crew of 4-5 men.
An "Old Reliable" of 1867[15] with its automatic sweep arm removed cut grain
from the reaper platform. This arm released one more man for other farm jobs.
Fig.16: The Automatic Self-Rake Reaper [15]
The McCormick "Advance" Combination Reaper and Mower. This machine was
manufactured and sold by McCormick from 1869-1879 [15]. The "Advance," a
combined mower and reaper, had an automatic rake as part of the reel. Platform
and reel were removable so that the machine could be used as a straight hay
mower. This illustration shows the machine for use as a reaper.
Fig.17 McCormick Combination Reaper and Mower [15]

The McCormick Marsh Type Harvester, built from 1875-1883, consisted of the
same cutting mechanism as McCormick's earlier reapers, with an elevator and
binding platform added. Two men rode on the platform, binding grain by hand as
it was delivered to the by the elevator. This machine was patented as early as
1858 but was not put into general use until 1875. With the Marsh type harvester,
2 men bound the grain while earlier harvesters had required 4-5 men for binding.
Fig.18 the Marsh Type Harvester [15]
McCormick Harvester and Binder of 1876 at work in the field was the first
practical self-binder ever built. People traveled miles to see the first machine
controlled by one man, which cut and bound grain in a single operation.
McCormick built and sold 50,000 of these binders between 1877 and 1885.
Fig.19 McCormick Harvester and Binder [15]
McCormick Harvester and Twine Binder manufactured in 1881[15]. This was

McCormick's first binder which tied the bundles with twine. After the

development of this machine, only minor improvements, tending to give greater

durability and lighter draft were added.
Fig.20: McCormick Harvester and Binder [15]
The McCormick Light Steel Binder built in 1888[15]. This was an improvement
over the first steel binder of 1885[15]. The knotter was improved for the first
time since the binder came into existence. Improvements in the reel construction
were made and an adjustable canvas grain shield was added on the rear of the
platform.
Fig.21 McCormick Harvester and Binder [15]
The McCormick-Deering Tractor Binder is operated from the Formal tractor

through the shaft running out of the rear, thus making the binder independent of
ground conditions. This power take-off, as it is called, is regularly supplied with
all Formal tractors. The binder, being independent of ground conditions, can

operate when a horse-drawn binder would find it difficult, if not impossible, to

cut grain.
Fig.22: McCormick-Deering Tractor Binder [15]
McCormick-Deering Harvester-Thresher is the most modern type of grain-

harvesting machine. It cuts 40-50 acres per day and threshes the grain, delivering
it after a thorough cleaning, into a grain tank. From the tank, the grain can be
drawn off into a motor truck or wagon and hauled to the grainer.

Fig.23 McCormick-Deering Harvester-Thresher [15]

This Windrow-Harvester cuts grain and leaves it in a windrow on top of the

stubble. After the grain cures on the stubble it is picked up by an attachment on
the platform and threshed. The windrow-harvester makes it possible to cut grain
earlier (avoiding natural hazards such as winds and hails) and to better harvest
woody grain (because the weeds dry out with the crops before threshing).
Fig.24 The Windrow-Harvester [15]

5. DESIGN OF MECHANICAL DRIVEN REAPER

5.1 Design parameters
The design specification or design parameters of this project are:
Manual or mechanical driven reaper for cereal crops.
Pushing or driving force 150-200N.
Plot to be harvest per day 2 hectare or 20000m2 per day.
8 working hours per day.
Average height of cereal crops 700mm.
5.2 Design concept
Design concept 1: design of mechanical reaper with gears as power transmission

from the carriage shaft to the intermediate shaft, flat belt for driving the
revolving reel, timing belt for driving the canvas or the plat form.
Design concept 2: design of mechanical reaper using V-belt as power

transmission from the carriage shaft to intermediate shaft and the others equal to
concept 1.
Concept 3: design of mechanical reaper the same as that of concept 2 but with
out any additional component to drive the plat form or the canvas drives directly
by the inclined shafts.
Concept 4: design of mechanical reaper with V-belt for power transmission from
the carriage shaft to intermediate and timing belt to drive the canvas plat form.

5.3 Design matrix
Design considerations Concept Concept Concept Concept

1 2 3 4
Material 6 9 9.5 8
availability(10)
Material cost(10) 5 7 9 9.5
Strength(10) 9 8 5 9
Design simplicity(5) 3 3 4.5 4
Manufacturability(10) 5 6 8 7
Weight(5) 3 3 4.5 4
Maintainability(5) 4 3 3 4.5
Effectiveness(10) 9.5 9 5 9
Operability(8) 7.5 5 4 7.5
Assembling(5) 4.5 3 3 4.5
Total value concepts 56.5 56 55.5 67
Table.1 Design matrices
As you see in the above table the fourth one or design concept 1 is better than the
others and it is selected to be designed.

5.4 Design analysis
5.4.1 Determining the relation ship of wheel and the overall speed ratio
Determining the radius of the wheel R and the overall speed multiply ratio X, the
distance traveled L, and the time require cutting L[cm] distance traveled by the
wheel t in order to operate the machine smoothly.
w * X
L w * R * t[cm]and L * l[cm]* 2t Where l is the length of the cutter
2
blade and the number 2 describes double bladed. Assuming the length of the
cutter to be 10cm
10* w * X 10* X
L = w *R *t = t R=

Comparing the values as in the table below to determine the preferred one:
R[cm] X[cm] D[cm]
12.73 4 25.46
19.1 6 38.2
25.5 8 52
31.83 10 63.66
38.2 12 76.4
Tabele.2 relation ship between R an X
From the above table I was selected the values with R=25.5 cm and X=8 in order
to have enough space for the driving V-belt pulley.
5.4.2 Design of the wheel

Calculating the thickness of or diameter of the ribs

1 when rib is at vertical position
F = 824.98
C =1100MPa
A = r2
C =F/ r2
r = 1.545mm
2 when the rib is at 30 0from the horizontal
F = 825/2cos300 = 476
This is less than the reaction force when the rib is at horizontal position.
For the manufacturing simplicity and strength take diameter of the rib to be d =
10 mm
Fig.25 wheel
5.4.3 Design of belt

transmission
5.4.3.2 Design of belts
Belt drives are being most widely used in industries for transmission of power
from one shaft to another over considerable distances. It is successfully
competing with individual drives in which the machine is directly couple to the
shaft of his own motor. The flexibility of the belt helps in arranging the shafts of
the driving and the driven pulleys in any manner and in using as many pulleys as
possible. The materials of the belts to be used for transmission must be strong in
tension, flexible and pliable, durable, relatively light in weight, and have good
frictional surfaces. The most commonly used materials are:
1. Leather
2. Fabric and canvas belts
3. Rubber belts
4. Balata belts etc
Belt joints and fasteners
Unless the belts are endless, some type of fastener is required to join the two
ends of the belt length. And the efficiency of the belt depends on the type and the
place of joining or fastening the ends of the belt. For example cemented by belt
maker and cemented by other persons have the efficiencies of 1 and 0.98
respectively.
Working stress
Factor of safety for leather belt may be taken equal to 8 to 10. Factor of safety
for rubber and balata may be taken from 6 to 8. The working stress so obtained
must be multiplied by the efficiency of the joint to find the allowable stress.
Belt speed
The belt speed should not be very high since as the belt speed increases,
centrifugal force begins to pull the belt away from the pulley thus reducing the
efficiency.
Belt slip and creep
Some amount of slip is always present between the belt and pulley surfaces
when power is being transmitted. Amount of slip increases if the belt is over
loaded. It has been found that a slip of up to 3% increases the coefficient of
friction. Under normal condition a slip of about 1.5% to 2% is present. Due to
slip the speed of the belt and is less than the peripheral speed of the driving
pulley. Creep is also the phenomenon caused by the elasticity of the material.
The belt is stretched more on the tight side than on the slack side.
Coefficient of friction

The coefficient of friction between the belt and the pulley surface depends up on
the belt material, material of the pulley surface, the belt speed and pulley speed.
Center distance
The life of the belt is a function of the center distance between the driver and
driven shaft. The shorter the belt the more often it will be subjected to additional
bending stresses while turning around the pulley at a given speed and quicker it
will be destroyed due to fatigue so the center distance is chosen so as to increase
the life of the belt.
Design of the first transmission belt drive [16]
Given power p=63.64w, Angular speed N=22.92 rpm
Pulley diameters large pulley diameter D=250mm and
Small pulley diameter d=75mm
Type of belt V-belt
A-section
Figure.26 of the pulleys
1. Determining the wrap angle of each pulley 1and 2 .

2 2 2
1 2

2 2 2
2 2
2. Determining center distance between pulleys C.
Recommended value of C is:
D<C<3(D+d) 250<C<975
Taking C=600mm.
3. determining length of the belt
Dd
L D d 2C sin cos Where sin
2 2C
D d 175 175 2
sin sin 1 cos 1
175
2C 1200 1200
1200
L 1723.2mm Taking the nearest from standard table of belt lengths
L=1750 mm.
Then the corrected value of center distance will be
2
2
C 0.25 L D d L D d 2 D d
2 2

C 613.5mm
Also the actual wrap angles also
D d 175 175
sin 1
2C 1227 1227
4. Determining speed of the belt
DN1
V 0.3m / s Where D=250mm and N1 =22.93 rpm.
60

5. determining the slack and tensile forces on the belt

Fmax V2 e cosec min

Fmin V2
This relation specifies the maximum ratio of belt tension which a given
belt/pulley interfaces can support with out gross slip. The V 2 term often
conveniently if erroneously referred to as the centrifugal tension detracts from

the interfaces useful tension capabilities.
f cos ec As the effective coefficient of friction which reflects the

amplification of the actual coefficient by wedging action in the groove of angle
.
Fmax V2 e f min

Fmin V2

Where f min min f1, f2 f2
From table f =0.512 and 2 =2.85537 rad f min =1.462
From standard table the power rate per belt having belt properties
A- Section V-belt, minimum pulley diameter=75mm and maximum angular

speed N2=75.62 rpm. Is:
Pr/z=0.0925 Kw/belt =92.5w/belt.

The correction factor of the power rating per belt with speed ratios greater than 2
is 0,009Kw/belt
Pr/z =101.5w.
Fmax Fmin V Pa / z Where V speed of the belt is, P is actual given power
a
and z is number of belts.
Pr
Also V 2 Fmax where k is the drive property of the belt?
zk V
f P 2
k 1 e min 0.768 Thus, Fmax r V Will be
zk V
=440.547 N where P r/z =101.5w.and =0.09682 from table which is

materials property.
6. Determining fatigue strength
The overall severity of belt loading on each of the two pulleys may thus be
expressed as an equivalent damaging force F*.
M
F* Fmax and
1 D
M
F2* Fmax
d
Where M=23.93 NM is a constant of proportionality which is experimentally

obtained value or it materials property.
F* 536.267NandF* 919.147N
1 2
7. determining the belt life

m
F
N* Where N * life cycle of the belt, F is the reference load and m is
F*
the index. F and m are constant properties of the belt with values 3216N and
11.11 respectively.
m m

F F
N* 4.394*108 cycle And N* 1.104*107 cycle
1 * 2 *
F F
1 2
Miners rule states that failure occurs when the cumulative damage via both
mechanisms reaches 100% [16]
N N
1 2 1
I.e. * where N1 = N 2 = N c where N c is the combined life of the
N N*
1 2
belt.
Nc Nc N* * N*
Hence * * 1 Nc *1 2 1.0772*107 cycle
N
1
N
2 N N*
1 2
The drive life time T will be
T
Nc L 7
6.2836*10 sec

6.2836*107
5.9year Where L is length of
V 365*8*60*60
the belt, V is speed of the belt and N c is the combined life of the belt
8. Determining number of belts
Pa Actual given power, Pr rated power, z number of belt, S f service factor, and
K L length correction factor.
P
Pa 63.64w , r 101.5w / belt Sf 1.3 assuming medium shock and K L 1
z
for length L=1750 from table

S * Pa
z f 0.815
Pr Taking the nearest whole number
KL *
z
z 1belt
5.4.3.2 Design of flat belt drive
Given power p=58.867 assuming the efficiency of the first belt to be 92.5%,
Angular speed N1=76.4 rpm
Pulley diameters large pulley diameter D=100mm and
Small pulley diameter d=80mm
Type of belt Flat belt
Material type Oak tanned leather with properties =1000Kg/m2
1. determining the length of belt
Assuming the center distance C=600mm
2
D d
L 2C
4C

2
D d
L 1482.933 Approximating to the next standard
L 1509mm
Now lets calculate the correct or the actual center distance C
2 2
C 0.25
L 0.5 D d L 0.5 D d

2 D d

C 613mm
2. determining angle of contact or contact arc

sin D d 0.0163 0.0163rad

2C
1 2 3.11rad And 2 2 3.174 where 1 and 2 are the
contact angles of pulley 1 and pulley 2.
3. determining speed of the belt Vb
Vb 1 s V 0.98V Where s=0.02 is the slip and V is the speed of the driver
pulley which is given by
dN1
V 0.32m / sec Where N1 and d are the speed and diameter of the first
60
pulley
Vb 0.3136 Since this speed is too small the effect of centrifugal force will
be neglected.
4. Determining the tight and slack side tensions F1 , and F2 respectively
The torque T is given by
F1 F2 V T 260P
N
7.33Nm
1
F1 F2 23.384N .. [1]
And also from the logarithmic relation

F

1
F
2.3log 2 0.25*3.1183
min
F
1 2.178
F
2
F 2.178F ......................... 2
1 2
Solving equations 1 and 2 simultaneously
F 19.85 And F 43.2346

2 1
Determining the belt section
F
b*t 1
Where f t is the allowable tensile stress of the belt material and C1
f t *C1
is the corrector factor
C =1 for oak tanned

1
f t 2.7Mpa For oak tanned leather
t=5mm for oak tanned leather thickness of
43.2346
b 3.2mm But taking the smallest belt width from standard
2.7 *5
b 25mm
Figure cross section of the flat belt
5.4.3.3 Design of timing belts [17]

From the structure the center distance c of the pulley is given of fixed as 980mm
and from table of American standard timing belts with XL cross-section, above
10 numbers of grooves Pb the pitch length or distance is 0.2 inch = 5.08 mm
Fig.27 sectioned timing belt [17]
Note: dimensions are in inches and ( ) are in mm
The length of the belt L = (r1+ r2) + 2C
Since r1 =r2 = r = 0, L =2 r + 2C =2 r + 1960
Assuming the no of teeth of the timing pulley be np =15
Perimeter of the pulley will be P =15*5.08 = 76.2
Radius of the pulley y will be r = p/2 = 12.13, d =24.26 mm
L = (24.26) +1960 =2036.215 up on adding correction factor L =2042mm
The number of teeth of the belt will be nb = 402

5.4.4 Design of bevel gear [19]
Fig.28 bevel Gears
Fig.29 cross sectional view of the gears
Assuming efficiency of the V-belt is to be 0.925

Power transmitted to the upper shaft will be 0.925P, p = actual given power
and 0.925 is the efficiency of the belt. The new power will be p = 0.925*63.64 =
58.867W
The input speed for this gear is the output speed of the belt
N1 D 250 22.92

N2 d 75 N2
N 2 76.4rpm This is the in put speed for the gear.
Gear ratio=2.4
Purpose: to change direction of motion & multiplying speed.
Material selection:
Through hardened steel of type Grade 1 for both gear & piston HB =250
Assumption:
working condition temperature is below 60oc
Reliability factor =99% K r 1
Pressure angle = 20o
Number of teeth of the pinion Z p 12
Module m=5 mm
Factor of safety Fs 2.5
And an assumed life of 8 hrs per day, 200 days per year for 15 years.

5.4.4.1 Design analysis
Determining the peripheral speed of the gear
Vp 0.11 Pin * Nin * N out Where N out 2.4 * Nin 183.36rpm
Vp 0.11 0.058867 * 76.4 *183.36

Vp 0.5895m / sec
Determining number of teeth and the pitch angles of the pinion and gear
ZG 12 * 2.4 28.8 ; 29
p1 tan
1

1
V.R
o o
22.62 And p2 90 p1 67.38 where V.R is the
speed ratio of the gears and p1 , p2 are the pitch angles of the pinion and gear
respectively.
Determining the formative number of pinion and gear teeth Z Ep , Z EG
respectively.
Z Ep Z p1 sec p1 13
Z EG Z p2 sec p2 76
Determining tooth form factor of pinion and gear respectively
0.686
y p1 0.124 0.0668
Zp1
0.686
y p2 0.124 0.1
Z p1
60P
Torque on the pinion is given by T 2N 3066Nmm
p1
Tangential load on the pinion Wt is given by

2T
Wt 102.192N
mZp
dp
Cone length l 80mm
2sin p1
For successful operation of the bevel gear the recommended face width is
6.3m f 9.5m
31.5 f 47.5
Take f 40mm
Addendum a m 5mm
Dedendum d 1.2m 6mm
Outer diameter of the pinion d op d p 2a cos p1 70mm
Internal diameter of the pinion d ip d p 2a cos p1 51mm
5.4.4.2 Checking strength of the pinion
1. Checking for pitting strength
1000Wt K A K v K HB Z x Z xc
c Z E Where
f * d p * Z1
c =calculated contact stress
Wt =tangential force
K A =over load factor
K HB =load distribution factor
Z x =size factor for pitting strength
Z xc =crowning factor for pitting strength
f =face width
d p =pitch diameter of the pinion
Z1 =inertial factor for pitting strength
Z E =elastic coefficient Z 190

E N / mm 2
The permissible contact strength will be
Z Z
cp clim NT w Where
Sfc*K *Zz
clim = allowable contact stress
Z NT = stress factor cycle
Z w = hardness factor
Sfc = contact safety factor
K = temperature factor
Z z =reliability factor
K v = Dynamic factor
cp = permissible contact stress for pitting
From the American gear manufacturing association (AGMA) equation factors
Over load factor K A =1
Contact safety factor Sfc =2.5
Dynamic factor K v
B 2

Kv A
Where A 50 56 1 B , B 0.25 12 Q 3 and Q v 6
v
A 200V
K v 1.148
Load distribution factor K HB
6 2
K HB K mb 5.6 *10 *f Where f is face width and K mb 1 for both
members straddle.
K HB 1.009
Size factor for pitting Z x
Z x 0.00402 * f 0.4375 For 12.7 f 114.3
Zx 0.6343
Stress cycle factor for pitting Z NT
0.0602 Where N is the life cycle 8

Z NT 3.4822N N 2.64 *10
Z NT 1.0836
Hardness ratio factor Z w
HB1
Zw 1 1 Where HB1 and HB 2 are the hardness of pinion and gear
HB2
but since the made of the same material
Zw 1
Temperature factor K 1 for T 1200c
Reliability factor Z z 1 for reliability=0.99
The elastic coefficient Z 190

E N / mm 2 for steel
Allowable contact stress clim
clim 2.35HB 162.89 750.39Mpa Where the hardness HB=250Mpa

Z Z
cp clim NT w
Sfc*K *Zz
cp 325.25 Mpa
1000Wt K A K v K HB Z x Z xc
c Z E
f * d p * Z1
c 118.4 Mpa since this value is less than the permissible contact stresses
the design for pitting is safe.
2. Checking for bending
Fundamental bending stress equation b
1000 * Wt * K A * K V YX K H
b And
f * d * m * YB * J
Permissible bending stress equation bp
blim * YNT
bp Where
Sfb * K A * YZ
b =Calculated bending stress
Wt =Tangential force =102.192N
K A =1 over load factor for bending
K V =Dynamic factor for bending
=1.148
YX =Size factor for bending
K H =1.009 Load distribution factor for bending
f =Face width of the pinion

d =Pitch diameter of the pinion
m =Module
YB =Length wise curvature factor for bending
J =0.24 bending strength geometry factor
bp =Permissible bending stress
blim =Allowable bending stress
YNT =Stress cycle factor for bending
Sfb =Safety factor for bending
K =Temperature factor for bending
YZ =1 Reliability factor for bending
From AGMA equation factors
Size factor YX
YX 0.4867 0.008339m 0.5367
Length wise curvature factor YB 1 for strait bevel gears
Stress cycle factor YNT
0.323 For 6 10
YNT 1.683N 3 *10 N 10 where N is the life cycle
YNT 0.8996
1000 * Wt * K A * K V YX K H
b
f * d * m * YB * J
b 18.90785Mpa And

blim * YNT
bp Where blim 0.3HB 14.48 89.48
Sfb * K * YZ
bp 32.1985 Since b bp design of the pinion is safe for bending.
5.4.4.3 Checking strength of the gear
Since the pinion and gear are made of the same material. Having the same stress
and strength as the pinion with small dimensions is safe it is true that the design
of the gear with larger dimensions is safe.
Determining the dimensions and values of the gear
Number of teeth of the gear ZG 29
Pitch diameter of the gear DG mZG 145mm
DG
Cone length of the gear L G 2sin 79 where p2 =67.38 pitch angle of
p2
the gear
Addendum a=m=5mm
Dedendum d=1.2m=6mm
Face width f=40mm
Clearance c=0.2m=1mm
Thickness of tooth t=1.5708m=8mm
Working depth =2m=10mm
Outer diameter of the gear DOG DG 2a 155mm
Inner diameter of the pinion D IG DG 2a 135mm

5.4.5 Design of shafts [19]

Given material steel with material properties of
Steel 1018 with yield strength, y =320Mpa &
Ultimate strength 341Mpa
A shaft is a rotating member, usually of circular cross section used to transmit

power or motion. It provides the axis of rotation, or oscillation, of elements such
as pears, pulleys, flywheels, cranes, sprockets, and the like and controls the
geometry of their motion.
A shaft design really begins after much preliminary work, the design of the
machine it self will dictate that certain gears, pulley, bearings, & other element
will have at least been partially analyzed and their size and spacing tentatively
determined. At this stage the design must be studied from the following points of
view
1. Deflection and rigidity
A. bending deflection
B. torsional deflection
C. slop of bearings & shaft-supported elements
D. shear deflection due to transverse loading of shot shafts
2. Stress and strength
A. stating strength
B. fatigue
C. reliability

5.4.5.1 Carriage shaft design analysis
F1 Fmax Fmin Of the belts
F1 Fmax Fmin Of the belts
=440.457+228.413
=668.96N
W= mg =100*9.81 = 981N
Where, m=mass of the over all structure of the machine
w F1 981 668.98
F2 2

2
824.98N
From American standard tubes and pipes select the internal diameter and
calculate the outside diameter to get the safe dimension or select from the
standard i.e.
Take d=23.5mm
p=63.64
ult = 341Mpa, y = 220Mpa , factor of safety, Fs 2.5
The figure below shows or indicates the overall shaft geometry, free body
diagram of the reaction forces, the shear force diagram and the bending moment
diagram of the shafts.

Note: A and B are the reaction forces right and left side of the bearings
Taking moment at A
M A 0 700R B 824.98 * 685 824.98 *15 668.96 * 350
R B 490.5N
Fx 0 R A 490.5
Torque (T) developed by the pulley is given by

T Fmax Fmin * R P , where R P = pulley radius
= (440.457- 228.413) *250
= 53011N.mm
As shown in the diagram above Tmax =53011Nmm & M max =104693.3Nmm at

the center or middle of the shaft.
From the concept of shafts subjected to combined twisting moment and bending
moment.
Let Te be the equivalent Twisting moment &
M e Be the equivalent bending moment & expressed as
Te
2 2
Tmax M max & M e 0.5 M max 2
Tmax M max
2

3

Te * D * 1 K
16
4

Me

32
3 4

* b * D 1 K Where d = internal diameter,
d
D = external diameter & K
D
In this case T = 53011Nmm & M = 104693.3Nmm

3 ult
Te 117.35 *10 Nmm And F 136.4N / mm
2
s
D
3
1 K 4 4381.63466mm2
Now lets calculate and analyze d & D and compare with the standards Using
equation of twisting & bending moments.
And using the equivalent bending moment
Me

32
3

* b * D 1 K
4

2
= 104753.2268, b 220N / mm
D 4 4850.63D d 4
The minimum outer diameter D will be 25mm for more safe and comfortable
lets take D=30mm & d=23.5mm by using these values. Lets check the strength
32Me 2
b 63.384N / mm

D3 1 K 4
=63.384 N / mm 2 which is less than the yield strength i.e. 220 N / mm 2
5.4.5.2. Design of the upper or the second shaft
Material properties the same as that of first shaft
With ult 341Mpa and b 220Mpa
Factor of safety Fs 2.5
Tangential load of the bevel gear Wt 102.192N angular speed of the shaft is
N 76.4rpm , power is P=58,867W tensions on the first or V-belt pulleys
T1 440.457N and T2 228.413N , tensions on the second flat belt pulleys
F1 43.2346N and F2 19.85N .

Fig of the second shaft with external forces applied on it
Axial force Wa is given by
Wa Wt tan cos G 102.192* tan 20*cos 67.38
Wa 14.306N
Radial force Wr is given by
Wr Wt tan sin G
Wr 33.252N
Components of the force due to tensions of the second pulley which is inclined at
an angle of 200 from the horizontal
F1x F1 cos 20 40.627N And F2x F2 cos 20 18.653N and the y component
force will be: F1y F1 sin 20 14.787N and F2y F2 sin 20 6.789N
Moment due to axial load M Wa * R Gp 1037.185N where R Gp is pitch radius
of the gear and Wa is radial force.
Since the power transmission between the gears is at 45 0 from the horizontal the
moment reactions are also at 450.
M x M cos 450 M y 733.4Nmm

Fig: that shows free body diagram, shear force and the bending moment diagram
of the shaft along X-axis and Y-axis.
Free body diagram of the forces along the Y-axis
M A 0 R by 351.5545N And from
F y 0 R Ay 305.5045N
Fig free body diagram of the forces on the shaft
M A 0 R bx 76.48N And from
F y 0 R Ax 8.64N

Taking the local extreme points to find the maximum bending moment
Point1. At 123 mm distance from the left end
M1 M x 2 M y 2 3537.82 3537.82 5003.2Nmm
2125
2
M2 1348592 134876.341Nmm
7787.8 1373.625 7908.01Nmm

2 2
M3
Then the maximum bending moment developed on the shaft will be
M max max M1 , M 2 , M 3 134876.341Nmm
The torque T is also given by
60P 60*58.867
T 7357.833Nmm
2N 2* *76.4
From shafts subjected to combined twisting moment and bending moment design
analysis. The equivalent twisting Te and moment M e are given by
Te M 2 T 2 135076.8858Nmm

M e 0.5 M M 2 T 2 134976.6134Nmm
1. calculating the diameter of the shaft using the equivalent twisting

moment
16Te
d3 17198.53mm 3
all
d 17.5mm 18mm
2. calculating the diameter of the shaft using the equivalent bending

moment

32M e
d3 6249.366
b
d 18.42mm 20mm
Taking the big and material availability the diameter will be d=20mm
5.4.6 Design of the structure
Fig.30 the structure
From design analysis of the upper shaft or the second shaft the reaction forces on
the upper parts of the structure are:
R Ax 36.957N R Bx 76.48N
And
R Ay 305.5045N R By 351.5545N
Fig free body diagram of the reaction forces
M R1 0 R 2y 212.76N And R 1y 138.8N
Fig bending moment and shear force diagram
As it shows in the above diagram
M max 59573.44Nmm And considering the structure is made of hollow steel
32M d
pipes and tubes: D 1 K where K
3 4
and d=internal diameter and
D
D=outer diameter of the structure material.
b 220Mpa That is Similar to that of first shaft or carriage.

32M
D4 d 4 D 4 2758.2276D d 4
* b
Taking different values of D from standard tables of dimensions of steel pipes

and tubes and checking the value of d.
D=21.336mm d=19.626 but the standard internal diameter of the pipe for the
given outer diameter D is d=15.8mm.which describes using the design is safe.
The outer diameter D=0.84in=21.336mm and the internal diameter

d=15.8mm pipe is used as structure of the material.
For the vertical structure take the maximum force from the above analysis of the
reaction force on the stand F2y 212.76N
Fig cross sectional area of the member
Now checking the compression strength of the vertical member of the structure
By taking the material as that of before the cross sectional area of the member
D2 d 2 F
will be A 205.584896mm 2 and the compression stress c =
4 A
4F
= 4.14Mpa
D d2
2
That is less than the allowable compressive stress.
Checking welding strength for carriage of the revolving reel
Fig.31 carriage of the revolving reel

Assuming the size weld to be 5mm and the weight of the revolving reel to be 16
KG which accounts the weight carried by each structure will be 8KG.
F=mg=8*9.81=78.48N, for butt welding bending stress b 80Mpa , allowable
shear stress all 27.5Mpa , safety factor SF 2.5 , length of weld l * D , Area
of weld A * D * t , thickness of the weld t=0.707s, and size of the weld
s=5mm.
A 236.95mm 2 The checking for shear
F 78.48N
0.33Mpa Which is much less than the allowable given
A 236.95mm 2
stress that indicates the revolving reel is safe under shear.
Checking for bending:
M
b Where b is the bending stress, M is bending moment and Z is section
Z
modulus.
* t * D3
M F*e 78.48*380 29822.4Nmm And Z 107864.44mm3
4
M 29822.4Nmm
b 0.2765Mpa Which is much less than the
Z 107864.44mm 3
allowable bending stress of the given material. The taking the same material as
before is safe.
D=21.336mm and d=15.8mm are the internal and external diameters of the
member.
Checking the strength of stand for the upper shaft:
Fig the stand of the upper shaft
Taking the most loaded stand of the two R x 76.48N , R y 351.554N ,
all 27.5Mpa all 136.4Mpa

for welding and for steel
all 32Mpa all 220Mpa
Checking for shear of the material
F
Area of shear A s l* t , where l=21.336mm is length of the member and t
A
is the thickness.
F F F
t 0.026mm
A l* t *l
Checking for compression
F F F
all t 0.076mm But for safety and easiness take t=4mm
A c l* t all *l
Checking for weld
Taking size of the weld S=5mm, Area of weld
F 76
A=2tl=2*0.707*5*21.336=15.8455mm2 and 0.5Mpa
A 15.8455
Since this is less than the allowable stress the structure is safe.
Checking the strength of the weld at the joint of the bearing
Fig
Assuming that half of the weight at a 280mm distance from the bearing to be
40KG, all =27.5Mpa, all =32Mpa, area of the weld

A *D * t * 21.336*5*0.707 236.83 and,
40*9.81* 4
1.0975Mpa which less than the allowable stresses.
* 21.336*5*0.707
Using the same material as before is acceptable and the selection is

reasonable and safe.

5.4.7 Design of pulley

5.4.7.1 The first transmission pulley or the V-belt pulleys
Material:
Cast iron because of its low cost
Allowable bending stress of cats iron 15Mpa
Density =7200KG/m3
Angle of the grove from vertical 17 0
Width of the grove at its pith diameter w
Half width of the pulley f
Diameter of the shaft d=30mm
1. Driver pulley:
Pitch diameter of the pulley D=250mm
Diameter of hub d1
Diameter of the rim D r
Length of the hub L
Velocity of the rim V
Major axis a1 and minor axis b1
Thickness of the pulley rim t
Fig.32 cross section of the pulleys arm

* D * N * 250* 22.92
Velocity of the rim V 0.3m / sec where N is the
60 60
angular speed of the pulley
Recommended value or sizes and dimensions of the pulleys are:
d1 2d =60mm
L 0.5d 48mm
D D
2mm t 3mm
300 200
2.833mm t 4.25mm
Take t 4mm
D r 250 2 t d 218mm Take D r = 210mm
Determining cross sectional area of the arms:
It is usually elliptical with major axis ( a1 ) and minor axis ( b1 ) which is equal to
half of the major axis.
The tangential load per arm Wt is given by:
2T 2* 26.515
Wt 106.059N Where: T is the torque R is the pitch radius
R * n 0.125* 4
of pulley and assuming the number of arms n=4
From table the recommended values of a, c, w, and f is:
a=3.3mm, c=8.7mm, w=11mm and f=10mm
The maximum bending moment on the arm is developed on root of the hub and
is given by:
M Wt * R 13257.357Nmm And section modulus Z is given by

* b1 a1 But b1 0.5a1
2
Z
32


* a1
3
Z
64
The bending stress of the arm is given by:

1 1
M 64M 3 64*13257.357 3 all
b a1 26.21mm Where b
Z * all *15
Take a1 =28mm and b1 =14mm
Fig.33 Driver V-belt pulley
2. The driven pulley
Since the driven pulleys diameter is less than 200mm a solid pulley is used.
From the driver pulley a=3.3mm, c=8.7mm, w=11mm and f=10mm, and shaft
diameter d=12mm, pitch diameter of the pulley dp=100mm

Fig.34 driven-belt pulley
5.4.7.2 Design of pulleys for the second transmission or flat belt pulleys
Material:
Cast iron
Belt type flat belt
Power P=58.867W
Belt width b=25mm
Thickness of the belt t=5mm
Crowned height of the pulley h=3mm
Driver pulley
Width of the pulley w is given by
w=b+13mm=28mm
Diameter of pulley d p =80mm
Driven pulley
Width of pulley w=b+13mm=28mm
Diameter of pulley d p =100mm
Fig.35 pulley with full dimension

5.4.8 Design of the Revolving Reel

Given the speed of the driven pulley is the same as that of the intermediate shaft.
N 76.4rpm
1
Taking the number of linkage 6
The speed of the inclined shaft that drive the reciprocating mechanism
N 2 183.6rpm
Since the cutters have double blade during one revolution of the reciprocating
mechanism the cutter bade cutes on each forward and backward motion.
n=number of cut in one minute

367.2
=
6
=61.2
During one stroke of the blade leftward or rightward of the cutter the revolving
pass through one of the revolving reel linkage.
N = speed the revolving real
367.2
N
6
61.2
Revolution ratio from the intermediate shaft to the revolving reels shaft will be
N 61.2

N 76.4
1
R 0.8
Then from the standard table having speed ratio of 0.8
d 80mm
1
d 100mm
2
The internal length of the revolving reel equal to the length of total cutter blades

l = 1000mm. and taking the diameter of the revolving reel to be 560mm,

assuming that the lower tip of the revolving reel touches around or slightly
bellow the halve of the grain length.
Fig.36 revolving reel
5.4.9 Design of keys
Fig.37 key
1. Design of key for the firs shaft or the carriage shaft
Since the shaft is hollow or it is made of steel pipe it better to make the key
integrated by welding over it with a great care to avoid the damage of the shaft
and the key needs some preparation by grinding for welding.
To check the strength of the key as it is welded through out its circumference the
side to be welded, taking some arbitrary dimensions of the key and assuming
size of weld S=5mm to check the shear stress.

Area of the welded section is given as:
A 2 l w t 2 16 5 *0.707 *5 148.47mm 2 where: l=length of the key, w
is the width of the key and t is thickness of the welded section.
F
Where F is the tangent force developed at a distance r from the center of
A
60P 60*63.64
the shaft and is given by F 1767.65N P is the
2 * N * r 2 * 22.92*0.015
power, N the angular speed of the shaft and r is the radius of the shaft.
F 1767.65N
11.906Mpa all 27.5Mpa
A 148.47mm 2
Design of the key is safe.
2. Design of key for the second V-belt pulley, the Gear & pulley of the flat
belt on the upper shaft
Material:
Mild steel with all 60Mpa
Square key width W= height H
Diameter of shaft d=20mm
Power P=58.867W
Angular speed of the shaft N=76.4rpm
From table the recommended value of W and H for diameter of shaft d=20mm
W=H=6mm
Taking the length of the key l=16mm check for shear of the key
A s l* W 16*6 96mm 2
And the tangential force F on shaft at the distance of its diameter is give by:
60P
F =735.783N
2 * N * r
F
The shear stress =7.664Mpa which is less than the allowable stress.
A
Design of the key is safe.
3. Design of key for the pulley of the flat belt on the revolving reel shaft
Power P=58.867W
From table the recommended value of W and H for diameter of shaft d=12mm
W=H=5mm and taking l=20mm
60P
F =1532.882N
2 * N * r
Shear area A s l* W 20*5 100mm
F
15.33Mpa This is less than the allowable stress.
A
4. Design of key for the pinion and timing belt gears on the inclined shaft
Material:
Power P=58.867W
Taking W=H=5mm and l=20mm

Shear area A s l* W 20*5 100mm
60P
F =436.5N
2 * N * r
F
4.365Mpa This is less than the allowable stress.
A
The dimension of the key in table form is as shown below (table summary of
keys).
Key No. 1 2 3 4
Width w 5 6 5 5
Height H 5 6 5 5
Length l 16 16 20 20
Table 3.dimensions of keys

5.4.10 Selection of bearings and retaining rings
Fig.38 bearing
Fig.39 retaining ring
s D t G w d
12 10.9 0.6 11.35 0.7 0.33
14 12.9 0.9 13.25 1 0.38
16 14.7 0.9 15.1 1 0.45
20 18.4 1.1 18.85 1.2 0.58
Table.4 retaining ring dimensions: Where s is diameter of the shaft

5.4.11 Design of the reciprocating mechanism
Fig. 38 reciprocating mechanism part
If R is radius of the big circle, r is radius of the rod inserted to the big circular
with 5mm thickness and e is the eccentricity distance or the distance to be
offseted
2e 50, r 4mm
e 25mm
Considering the thickness of circular member after the rod and the eccentric
distance
Take R=25+4+5=34mm

5.5 Manufacturing process
1. The overall structure or the body is made up of from steel pipes and angle
iron (for the placement of the cutters) and manufactured by welding given the
overall dimensions and the parts in the analysis part.
2. The carriage shaft is made of hollow shaft steel pipe and is manufactured by
cutting the shaft for the required length, weld the key for the pulley, and drilled
for the bolts.
3. The cutters are hardened steels with double blades and are manufactured by
cutting, forging and grinding to attain the required shape and profile.
4. The upper shaft is a solid shaft and is manufactured by selecting with the
given diameter steel, cut in to the required length, machined for the key seats,
and drill for the thin holders.
5. Gears are manufactured from steel ingots by machining and hardened.
6. Canvas or the conveyor the timing belt, V-belt and the flat belts are buying
from market using the standard dimensions and specification in the analysis part.
7. The pulleys are manufactured by casting and some machining operation for
finishing.
8. Rivets and Bolts are also from markets of standard dimensions an

specification of the analysis.
9. The wheel is made of steel plates by selecting the material with the required
thickness and width cut in to the required perimeter of the wheel, rolled with
rolling machine to the approximate circle, and then welds the two ends of the
plate. Similarly the collar or small circular plate is prepared, mark the two
circular plates at every 600 s and finally cut steel rods taken as ribs and weld or
connect the two marks at the smaller and bigger wheel steel plates.
10. To increase friction between the wheel and the land, weld a 5 or 6mm
thickness steel with the same lengths as the width of the wheel at every 180.

11. The revolving reel shaft select the material with the given dimension, cut to
the required length, preparing the seat for the keys through machining and drilled
for the revolving reel to avoid relative motion.
12. The revolving reel is manufactured by preparing two circular steel pipes, 12
small steel plates to be welded at the circular pipes every 600 6 0f each, 6 long
steel plates with the dimensions given in the analysis part to connect the two
circular pipes by welding at the tip of each small steel plates.
5.5.1 Cost analysis
materials Unit Qty Total

cost(ETB) cost(ETB)
Cutters 50 12 600
Steel pipe 2.768* 50.00 2 100.00

21.336*12000
Steel pipe3.25* 100.00 1 18.00

30*1000
Angle iron 16.00 1 16.00

4*50*50*1200
Steel plate 6.00 1 6.00

2*50*1200
Steel plates 20.00 8/6 27.00

2*20*8000
Bolts and nuts 4.00 6 24.00
Bearings 30 35.00 2 70.00.
V-belt 40.00 1 40.00
Flat belt *1509 17/m.00 1 25.70
V- belt pulley 60.00 2 12.00

Flat belt pulley 40.00 2 40.00
Timing belt 80.00 2 80.00
Timing belt pulley 40.00 4 160.00
Wheel 50.00 2 100.00
Solid steel 30.00 1 30.00

20*1200

16*1200

12*1200
Solid steel 8*80 10.00 1 10.00
Machining cost 200.00 200.00
Labor cost 60.00 60.00
Welding cost 100.00 100.00
Other costs 100.00 100.00
Total cot required 1897.70
Table.6 cost analysis
As you see in the table the total cost for manufacturing of this reaping machine
is 1897.70 with no need of operational cost like fuels. When this reaper harvests
for 20 days continuously it harvest about 40 hectares but using the manual sickle
it needs 200 labors with a total price of 20*200=4000.00 ETB which is more
than the cost of the reaper makes its cost low and reasonable to farmers.
5.6 Assembling procedures
1. Prepare all the parts or machine components
2. Insert one washer of the pulley into the carriage shaft and pass through one
of the holes(from left side) of the structure or the body, insert the pulley, the
second washer, the wheel, the spacer, washer and passes through the second
hole(right side) of the structure. And moving the shaft to the other side (right
side) of the structure and insert the wheel, the spacer the washer, the V-belt and
returning to the correct positioning, insert the bearing and the washer.
3. Tighten the wheels with the carriage shaft and lock parts which require a
locker.
4. Insert the upper shaft through one of the upper stand holes(left side) pass the
shaft through retaining ring V-belt pulley retaining ring, V-belt, and through the
second hole(right side) the assemble the gear and the flat belt pulley according
their sides.
5. Arranging and ordering the lower cutters and placed on the angle iron tighten
with small flat bolts (the bolts are totally immersed in the cutter. Then the top
cutter will also be placed above the lower cutter and pinned using adjustable
pines.
6. carrying or holding the revolving reel between the two carriages insert the
revolving reel shaft through either side and pass through the retaining ring, the
pulley, retaining ring, the flat belt and revolving reel.
5.6.1 Working principle of Mechanical Driven Reaper
The source of power for all components of the reaper comes from the person
who drives it by rotating the wheels and the carriage shaft (That are connected
by bolts), transmits to the upper or intermediate shaft through V- belts, the
intermediate shaft drive the canvas and the reciprocating mechanism through the
bevel gear and the revolving reel through the flat belt drives.

6 CONCLUSION AND RECOMMENDATIONS

Ethiopia has great agricultural potential because of its vast areas of fertile land,
diverse climate, adequate rainfall, and large labor pool. Despite this potential,
Ethiopian agriculture has remained underdeveloped Because of a poor economic
base, low productivity, weak infrastructure (the agricultural tools and
instruments), and low level of technology. I concluded that this project or design
of mechanical driver helps to reduce these problems and avoids the most tedious
and handiwork harvesting (using sickles) with a reasonable cost and
performance for farmers.
I recommended that designing and making analysis of any machine or

components is nothing if and only if it translates or interprets to its handled level
manufactured level. This project should be continuing until it will be
manufactured and observing results check in fields and prototypes

7 REFERENCES
1. http://www.countrystudies.us/ethiopia
2. http://www.nationsencyclopedia.com/economies/Africa/Ethiopia-AGRICULTURE.html
3. http://www.americanartifacts.com/smma/grain/cradle.htm
4. CADU 1969 Progress Report No. 1. Implement Research Section. CADU Publication No. 32).
5. Henock Kifle. 1972. Investigations on Mechanized Farming and its Effect on Peasant
Agriculture. CADU Publication No. 74.
6. http://www.ferrari-tractors.com/walking.htm
8. http://www.alibaba.com/catalog/11222559/Direct_Planting_Machine.html
9. http://www.excelagr.com.au/partsacc_3.php
10. http://www.icajapan.org/virtualtoure/95EgyptE.html
11. http://en.red-dot.org/288+M5390a46003b.html
12. http://www.ilo.org/encyclopedia/?print&nd=857200015
13. http://www.ilo.org/encyclopedia/?print&nd=857200015
15. http://www.vaes.vt.edu/steeles/mccormick/harvest.
16. http://www.mech.uwa.edu.au/DANotes/V-belts/miscellany/miscellany.html
17. http://www.sdp-si.com/D790/PDF/D790C02006.pdf
18. Cecil Jensen & Jay D.Helsel, Engineering drawing and design, 5 th edition, Mc Graw-Hill,
1996, New York.
19. Joseph Edward Shigley & Charles R.Mische, Mechanical Engineering design, 5 th edition, Mc
Graw Hill, 1989, New York.
20. Robert C.Juvinal & Kurt M.Marshek, Fundamentals of machine components design, 3 rd
edition, John wiley, 1999, New York.
21. R.S. Khurmi & J K Gupta, A Text book of machine design, Eurasia, 2002, New Delhi.
22. http://www.engineeringtoolbox.com/ansi-stainless-steel-pipes-d_247.htm

APPENDIX

TABLE OF CONTENTS PAGE

ABSTRACT........................................................................................................................0
1. BACK GROUND AND JUSTIFICATION.....................................................................1
1.1 Scio economic conditions of Ethiopia.......................................................................1
1.2 Mechanical driven reaper..........................................................................................1
2. INTRODUCTION...........................................................................................................3
2.1 Farm mechanization...................................................................................................3
2.2 Simple Harvesting machineries and tools..................................................................3
2.2.1 Sickle..................................................................................................................3
2.2.2 Scythe.................................................................................................................3
2.2.3 Cradle..................................................................................................................3
2.2.4 Mowers...............................................................................................................4
2.2.5 Reapers...............................................................................................................4
3. OBJECTIVES OF THE PROJECT.................................................................................6
4. LITERATURE REVIEW.................................................................................................7
4.1 Agricultural machineries............................................................................................7
4.1.1 Soil tillage machines..........................................................................................8
4.1.2 Planting machines..............................................................................................9
4.1.3 Cultivating machines.......................................................................................10
4.1.4 Forage harvesting machines............................................................................12
4.1.5 Grain and fiber harvesting machines...............................................................12
4.1.6 Vegetable harvesting machines........................................................................13
4.1.7 Fruit and nut harvesting machines...................................................................13
4.1.8 Transport and elevating machines...................................................................14
4.1.9 Agricultural chemical applicators....................................................................14
4.1.10 Sorting and packaging machines...................................................................15
4.1.11 Power plants...................................................................................................15
4.2 Grain Harvesting and reapers [15]...........................................................................16
4.2.1 "Reaping Hook" or Sickle.....................................................................................16
4.2.2 Cradle................................................................................................................16
4.2.3 Scythe...............................................................................................................17
4.2.4 McCormick reaper............................................................................................17
5. DESIGN OF MECHANICAL DRIVEN REAPER.......................................................24

5.2 Design concept.........................................................................................................24
5.3 Design matrix...........................................................................................................25
5.4 Design analysis........................................................................................................26
5.4.1 Determining the relation ship of wheel and the overall speed ratio.................26
5.4.2 Design of the wheel..........................................................................................27
5.4.3 Design of belt transmission..............................................................................28
5.4.4 Design of bevel gear [19].................................................................................38
5.4.5 Design of shafts [19].........................................................................................47
5.4.6 Design of the structure......................................................................................55
5.4.7 Design of pulley................................................................................................59
5.4.8 Design of the Revolving Reel...........................................................................63
5.4.9 Design of keys..................................................................................................64
5.4.10 Selection of bearings and retaining rings........................................................68
5.4.11 Design of the reciprocating mechanism..........................................................69
5.5 Manufacturing process.............................................................................................70
5.5.1 Cost analysis.....................................................................................................71
5.6 Assembling procedures............................................................................................73
5.6.1 Working principle of Mechanical Driven Reaper.............................................73
6 CONCLUSION AND RECOMMENDATIONS............................................................75
7 REFERENCES...............................................................................................................76


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Design of mechanical driven reaper Farm technology

By Alemu Yamane Mechanical engg dept. 0

1. BACK GROUND AND JUSTIFICATION

Agriculture is an endeavor practiced in all countries. From the earliest times,

1.2 Mechanical driven reaper

Mechanical driven reapers are harvesting-machines used for cutting grain-crops.

The transmission part contains the transmission of the power or movement

By Alemu Yamane Mechanical engg dept. 1

Reciprocating mechanism is used to convert the rotation speed of the inclined

By Alemu Yamane Mechanical engg dept. 2

Agricultural mechanization helps in increasing production, productivity and

2.2 Simple Harvesting machineries and tools

Fig.1 harvesting man using cradle [3]

By Alemu Yamane Mechanical engg dept. 5

3. OBJECTIVES OF THE PROJECT

Objective of this project is investigating, acquiring, designing and implementing

By Alemu Yamane Mechanical engg dept. 6

4.1 Agricultural machineries

Farming in Ethiopia is also, generally labor intensive. However, in some

To the initial promotion of agricultural machinery

CADUs research section evaluated the performance of local farm

Machines various models of harvesting and threshing machines were

By Alemu Yamane Mechanical engg dept. 7

Technical feasibility and economic viability of the new methods were

The main consequences of introducing mechanical technologies during the

4.1.1 Soil tillage machines

Fig.2 Goldoni Secondary Tillage Machines [6]

By Alemu Yamane Mechanical engg dept. 8

Fig.3 Goldoni Grain Drill [7]

4.1.2 Planting machines

Fig.4 direct planting machine [8]

4.1.3 Cultivating machines

By Alemu Yamane Mechanical engg dept. 10

Fig.5 cultivating machine [9]

By Alemu Yamane Mechanical engg dept. 11

Fig.7 garden rake [11]

4.1.4 Forage harvesting machines

By Alemu Yamane Mechanical engg dept. 12

4.1.5 Grain and fiber harvesting machines

By Alemu Yamane Mechanical engg dept. 13

Fig.8 Combine for harvesting wheat without an enclosed cabin [13]

4.1.6 Vegetable harvesting machines

4.1.7 Fruit and nut harvesting machines

4.1.8 Transport and elevating machines

By Alemu Yamane Mechanical engg dept. 14

Fig.9 Fort Powered Trailers [14]

4.1.9 Agricultural chemical applicators

By Alemu Yamane Mechanical engg dept. 15

4.1.10 Sorting and packaging machines

4.1.11 Power plants

By Alemu Yamane Mechanical engg dept. 16

4.2 Grain Harvesting and reapers [15]

4.2.1 "Reaping Hook" or Sickle

Fig.10 Reaping Hook [15]

Fig.11 The Cradle [15]

By Alemu Yamane Mechanical engg dept. 17

Fig.12 The Scythe [15]

4.2.4 McCormick reaper

Fig.13 the World's First Reaper [15]

Fig.14 McCormicks Patent Reaping Machine [15]

Fig.15 McCormick's Patent Reaping and Mowing Machine [15]

The McCormick Automatic Self-Rake Reaper was originally patented in 1858

By Alemu Yamane Mechanical engg dept. 19

Fig.16: The Automatic Self-Rake Reaper [15]