DESIGN AND FABRICATION OF

SUGARCANE PEELER USING DEBURRING BRUSH

A DESIGN & FABRICATION PROJECT REPORT

Submitted by

KARHTIKEYAN B. 814716114049
MANIKANDAN J. 814716114056
MANIKANDAN S. 814716114057
MANOJ N. 814716114058

in partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING
in
MECHANICAL ENGINEERING

SRM TRP ENGINEERING COLLEGE

TIRUCHIRAPALLI

ANNA UNIVERSITY: CHENNAI 600 025

APRIL 2019
 ANNA UNIVERSITY: CHENNAI 600 025
BONAFIDE CERTIFICATE

This is to certify that this project report “DESIGN AND

FABRICATION OF SUGARCANE PEELER USING DEBURRING
BRUSH” is the bonafide work done by,
KARHTIKEYAN B. 814716114049
MANIKANDAN J. 814716114056
MANIKANDAN S. 814716114057
MANOJ N. 814716114058
who carried out the project work under the supervision.

SIGNATURE SIGNATURE
Mr. N. INDHUSEKARAN Mr. J. JONES PRAVEEN
HEAD OF THE DEPARTMENT SUPERVISOR
MECHANICAL ENGINEERING ASSISTANT PROFESSOR
SRM TRP ENGINEERING COLLEGE MECHANICAL ENGINEERING
TIRUCHIRAPALLI-621105 SRM TRP ENGINEERING COLLEGE
TIRUCHIRAPALLI-621105

Submitted for the project viva voce held on: _______________

INTERNAL EXAMINER EXTERNAL EXAMINER

 iii

ACKNOWLEDGEMENT
First we take this opportunity to thank lord almighty for his immense

blessings and our founder chairman Dr.T.R.PAARIVENDHAR, and our

chairman Dr.R.SHIVAKUMAR, towards the successful completion of our

project.

We also extend our thanks to our honorable Principal Dr.S.MALIKRAJ,

and our Head of the Department Mr.N.INDHUSEKARAN and project

coordinator Mr.N.PERIYASAMY Asst. professor for permitting us to do this

project and for all the support and guidance provided in completing the project.

Words are inadequate to express our indebtedness and sense of gratitude

to our guide Mr.J.JONES PRAVEEN, Asst. Professor who was all along with

us throughout our project work, and without him we could not have finished our

project successfully. We also thank our department staffs who directly and

indirectly helped in our project.

 iv

ABSTRACT
This project concentrates on the designing of sugarcane peeler
using deburring brush with simple mechanism at low possible rate.
The existing machine involves complicated design and it requires
more power and more space to function. Hence the manufacturing
cost is very high when compared with this design. But this model
involves a basic mechanism with efficient working that is achieved at
much lower cost. It is designed for peeling the sugarcane into desired
length, using easily available raw materials. The peeling feed rate of
the machine is set to constant. The machining works of various
components for this project are machined with lathe and radial
drilling machine, which is a common purpose machine in all
workshops. Sugarcane is a rich source of Magnesium. This work is
intended to help solving problem hindering in sugarcane peeling.

Keywords: Sugarcane, Peeling machine, Wire brush.

 v

TABLE OF CONTENTS

CHAPTER PAGE
TITLE
NO. NO.
ABSTRACT iv
LIST OF FIGURE vii
LIST OF TABLES viii
LIST OF SYMBOLS ix
1 INTRODUCTION 1
1.1 CULTIVATION 2
1.2 PRODUCTION 6
1.2.1 Ethanol 6
1.2.2 Bagasse 7
1.2.3 Electricity 7
1.2.4 Bio Gas 8
1.3 EXISTING MODEL 8
2 LITERATURE REVIEW 9
3 MACHINE COMPONENTS AND SPECIFICATION 12
3.1 STEEL WIRE BRUSH 12
3.2 USE OF WIRE BRUSH 13
3.2.1 Dimension of wire brush 13
3.3 SELECTION OF MOTOR 13
3.3.1 Motor 14
3.4 BELT 14
3.5 PULLEY 15
3.6 BEARING 15
3.7 BENEFITS OF DEEP GROOVE BALL BEARING 16
4 FACTORS DETERMING THE CHOICE OF MATERIAL 17
4.1 PROPERTIES 17
 vi

4.2 MANUFACTURING CASE 18

4.3 QUALITY REQUIRED 18
4.4 AVAILABILITY OF MATERIAL 18
4.5 SPACE CONSIDERATION 18
4.6 COST 18
5 CALCULATIONS 19
5.1 CALCULATION OF TORQUE 19
5.2 CALCULATION OF CUTTING SPEED 19
5.3 CALCULATION OF LENGTH OF THE BELT 20
6 WORKING PRINCIPLE 21
6.1 NEW DESIGN 21
6.2 WHILE FUNCTIONING 22
6.3 MERITS 22
6.4 DEMERITS 22
7 DRAFTING 23
7.1 PART DIAGRAM 23
7.2 ASSEMBLY DIAGRAM 23
8 ESTIMATION 32
9 CONCLUSION 33
REFERENCES 27
APPENDIX
 vii

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1.1 Cultivation 2
1.2 Existing model 8
3.1 Steel wire Brush 12
3.2 Stainless Steel wire Brush 13
3.3 V-Belt section 14
4.1 Bearing 6203 16
4.2 Bearing 6204 16
6.1 New design 21
6.2 While operating 22
7.1 Assembly diagram 24
 viii

LIST OF TABLES

FIGURE TITLE PAGE

NO. NO.
1.1 Product Specification 8
3.1 Product Specification 13
3.2 Motor Specifications 14
3.3 Belt Specifications 14
8.1 Project Estimation 32
 ix

LIST OF SYMBOLS

SYMBOL TITLE
mm Millimeter
rpm Revolution per minute
m/min Meter per minute
Nm Newton meter
W Watt
V Voltage
do Outer diameter
di Inner diameter
 CHAPTER 1
INTRODUCTION
The sugar cane family is made up of over 30 sugar cane varieties. Sugar
cane is a perennial grass that thrives in hot, humid locations like Brazil and
India. The sugar derived from sugar cane is used in syrups, juices, and
molasses, but the rest of the plant can also be used in the production of
environmentally friendly paper products. Sugar cane is a subtropical/tropical
grass that originated in Papua, New Guinea and spread throughout Southeast
Asia, India, the Mediterranean, and the Caribbean, Hawaii and the southern
United States because of human migration and the slave trade. The migrations
have also resulted in hybrid sugar cane plants. The juice from the sugar cane's
stalk is highly prized and is the source of 70 percent of the world's sugar. It also
has the highest number of calories per unit area of any plant. Fresh sugarcane
juice is a popular beverage in many countries particularly in Asian region such
as China, India, Malaysia and Thailand due to its taste and cheap price. It is
served in many eateries from roadside stalls to five-star hotel dining halls.
Additionally, sugarcane juice is used for the medication in some countries. For
instance, the Indian systems of medicine have utilized it to cure jaundice and
liver-related disorders. Flavonoids that can be found in sugarcane juice have the
abilities to protect cells from degenerative processes and to reduce the
development of health problems such as cancer and cardiovascular diseases.
Although the industrial production of sugarcane juice has a business potential,
the selling of sugarcane juice cannot be expanded as expected owing to its rapid
quality descent. The juice concentration is deemed as a solution to lengthen the
shelf-life, reduce the storage and shipping costs, and elevate the consumer
safety while preserving the fresh quality of sugarcane juice.

1
1.1 CULTIVATION

Sugarcane cultivation requires a tropical or subtropical climate, with

minimum of 60 cm (24 in) of annual moisture. It is one of the
most efficient photosynthesizes in the plant kingdom. It is a C4 plant, able to
convert up to 1% of incident solar energy into biomass. Once a major crop of
the southeastern region of the United States, sugarcane cultivation has declined
there in recent decades, and is now primarily confined to Florida, Louisiana,
and South Texas.

Fig 1.1Cultivation

Sugarcane is cultivated in the tropics and subtropics in areas with a

plentiful supply of water for a continuous period of more than six to seven
months each year, either from natural rainfall or through irrigation. Therefore,
most of the world's sugarcane is grown between 22°N and 22°S, and some up
to 33°N and 33°S. When sugarcane crop is found outside this range, such as

2
the Natal region of South Africa, it is normally due to anomalous climatic
conditions in the region, such as warm ocean currents that sweep down the
coast. In terms of altitude, sugarcane crop is found up to 1,600 metres or 5,200
feet close to the equator in countries such as Colombia, Ecuador, and Peru.

Sugarcane can be grown on many soils ranging from highly fertile well-
drained mollisols, through heavy cracking vertisols, infertile acid oxisols,
peaty histosols, to rocky andisols. Both plentiful sunshine and water supplies
increase cane production. This has made desert countries with good irrigation
facilities such as Egypt some of the highest-yielding sugarcane-cultivating
regions.

Although some sugarcanes produce seeds, modern stem cutting has

become the most common reproduction method.. Each cutting must contain at
least one bud, and the cuttings are sometimes hand-planted. In more
technologically advanced countries like the United States and Australia, billet
planting is common. Billets (stalks or stalk sections) harvested by a mechanical
harvester are planted by a machine that opens and recloses the ground. Once
planted, a stand can be harvested several times; after each harvest, the cane
sends up new stalks, called ratoons. Successive harvests give decreasing yields,
eventually justifying replanting. Two to 10 harvests are usually made depending
on the type of culture. In a country with a mechanical agriculture looking for a
high production of large fields, like in North America, sugar canes are replanted
after two or three harvests to avoid a lowering in yields.

In countries with a more traditional type of agriculture with smaller fields

and hand harvesting, like in the French island la Réunion, sugar cane is often
harvested up to 10 years before replanting. Sugarcane is harvested by hand and
mechanically. Hand harvesting accounts for more than half of production, and is
dominant in the developing world. In hand harvesting, the field is first set on
fire. The fire burns dry leaves, and chases away or kills any lurking venomous

3
snakes, without harming the stalks and roots. Harvesters then cut the cane just
above ground-level using cane knives or machetes. A skilled harvester can cut
500 kg (1,100 lb) of sugarcane per hour.

Mechanical harvesting uses a combine, or sugarcane harvester. The

Austoft 7000 series, the original modern harvester design, has now been copied
by other companies, including Cameco / John Deere. The machine cuts the cane
at the base of the stalk, strips the leaves, chops the cane into consistent lengths
and deposits it into a transporter following alongside. The harvester then blows
the trash back onto the field. Such machines can harvest 100 long tons (100 t)
each hour; however, harvested cane must be rapidly processed. Once cut,
sugarcane begins to lose its sugar content, and damage to the cane during
mechanical harvesting accelerates this decline. This decline is offset because a
modern chopper harvester can complete the harvest faster and more efficiently
than hand cutting and loading. Austoft also developed a series of hydraulic
high-lift infield transporters to work alongside their harvesters to allow even
more rapid transfer of cane to, for example, the nearest railway siding. This
mechanical harvesting doesn't require the field to be set on fire; the remains left
in the field by the machine consist of the top of the sugar cane and the dead
leaves, which act as mulch for the next round of planting. Sugarcane as food in
most countries where sugarcane is cultivated, there are several foods and
popular dishes derived directly from it, such as:

 Raw sugarcane: chewed to extract the juice

 Sayur nganten: an Indonesian soup made with the stem of trubuk
(Saccharum edule), a type of sugarcane.
 Sugarcane juice: a combination of fresh juice, extracted by hand or small
mills, with a touch of lemon and ice to make a popular drink, known
variouslyas air

4
 Syrup: a traditional sweetener in soft drinks, now largely supplanted in
the US by high fructose corn syrup, which is less expensive because of
corn subsidies and sugar tariffs.
 Molasses: used as a sweetener and a syrup accompanying other foods,
such as cheese or cookies
 Jaggery: a solidified molasses, known as gur, gud, or gul in India, is
traditionally produced by evaporating juice to make a thick sludge, and
then cooling and molding it in buckets. Modern production partially
freeze dries the juice to reduce caramelization and lighten its color. It is
used as sweetener in cooking traditional entrees, sweets and desserts.
 Falernum: a sweet, and slightly alcoholic drink made from sugarcane
juice
 Cachaça: the most popular distilled alcoholic beverage in Brazil; a liquor
made of the distillation of sugarcane juice.
 Rum: is a liquor made from sugarcane products, typically molasses but
sometimes also cane juice. It is most commonly produced in the
Caribbean and environs.
 Basi: is a fermented alcoholic beverage made from sugarcane juice
produced in the Philippines and Guyana.
 Panela: solid pieces of sucrose and fructose obtained from the boiling
and evaporation of sugarcane juice; a food staple in Colombia and other
countries in South and Central America
 Rapadura: a sweet flour that is one of the simplest refinings of sugarcane
juice, common in Latin American countries such as Brazil, Argentina and
Venezuela (where it is known as papelón) and the Caribbean.
 Rock candy: crystallized cane juice

5
1.2 PRODUCTION

Global production of sugarcane in 2016 was 1.9 billion tonnes, with

Brazil producing 41% of the world total and India 18% (table). The average
worldwide yield of sugarcane crops in 2016 was 70.6 tonnes per hectare, led
by Peru with 112 tonnes per hectare and Zambia with 103. The theoretical
possible yield for sugar cane is about 280 tonnes per hectare per year, and small
experimental plots in Brazil have demonstrated yields of 236–280 tonnes of
cane per hectare, Other promising regions for high-yield sugarcane production
are in sun-drenched, irrigated farms of northern Africa, and other deserts with
plentiful water from nearby rivers or irrigation canals.

In the United States, sugarcane is grown commercially

in Florida, Hawaii, Louisiana and Texas.

1.2.1 Ethanol

Ethanol is generally available as a by product of sugar production. It can be

used as a biofuel alternative to gasoline, and is widely used in cars in Brazil. It
is an alternative to gasoline, and may become the primary product of sugarcane
processing, rather than sugar.

C6H12O6 – 2C2H5OH + 2 CO2

In Brazil, gasoline is required to contain at least 22 % bioethanol. This

bioethanol is sourced from Brazil's large sugarcane crop. The production of
ethanol from sugar cane is more energy efficient than from corn or sugar beets
or palm/vegetable oils, particularly if cane bagasse is used to produce heat and
power for the process. Furthermore, if biofuels are used for crop production and
transport, the fossil energy input needed for each ethanol energy unit can be
very low. EIA estimates that with an integrated sugar cane to ethanol
technology, the well-to-wheels CO2 emissions can be 90 percent lower than
conventional gasoline.

6
1.2.2 Bagasse Application

Sugarcane is a major crop in many countries. It is one of the plants with

the highest bioconversion efficiency. Sugarcane crop is able to efficiently fix
solar energy, yielding some 55 tonnes of dry matter per hectare of land
annually. After harvest, the crop produces sugar juice and bagasse, the fibrous
dry matter. This dry matter is biomass with potential as fuel for energy
production. Bagasse can also be used as an alternative source of pulp for paper
production. Sugarcane bagasse is a potentially abundant source of energy for
large producers of sugarcane, such as Brazil, India and China. According to one
report, with use of latest technologies, bagasse produced annually in Brazil has
the potential of meeting 20 percent of Brazil’s energy consumption by 2020.

1.2.3 Electricity Production

A number of countries, in particular those devoid of any fossil fuel, have

implemented energy conservation and efficiency measures to minimize energy
used in cane processing and furthermore export any excess electricity to the
grid. Bagasse is usually burned to produce steam, which in turn creates
electricity. Current technologies, such as those in use in Mauritius, produce over
100 kWh of electricity per tonne of bagasse. With a total world harvest of over
1 billion tonnes of sugar cane per year, the global energy potential from bagasse
is over 100,000 GWh. Using Mauritius as a reference, an annual potential of
10,000 GWh of additional electricity could be produced throughout Africa.
Electrical generation from bagasse could become quite important, particularly to
the rural populations of sugarcane producing nations. Recent cogeneration
technology plants are being designed to produce from 200 to over 300 kWh of
electricity per tonne of bagasse. As sugarcane is a seasonal crop, shortly after
harvest the supply of bagasse would peak, requiring power generation plants to
strategically manage the storage of bagasse.

7
1.2.4 Biogas Production

A greener alternative to burning bagasse for the production of electricity

is to convert bagasse into biogas. Technologies are being developed to
use enzymes to transform bagasse into advanced biofuel and biogas.

1.3 EXISTING MODEL

Fig 1.2 Existing Model

Table 1.1 Product Specifications

Capacity 100-150 Kg/hr
Product to be peeled Sugarcane
Voltage 220 V
Frequency 50/60 Hz
Motor Power 1-2HP

8
 CHAPTER 2
LITERATURE REVIEW
Immink MDC, Viteri FE (1981) Energy intake and productivity of
Guatemalan sugarcane cutters: An empirical test of the efficiency wage
hypothesis part I. J Dev Econ 9(2):251–271This study represents an empirical
test of the productivity consumption relation of the efficiency wage hypothesis,
which is briefly discussed here. The research setting and design of the study are
described. An energy supplementation program was generally effective in
raising the daily energy intake and energy expenditure levels of Guatemalan
sugarcane workers who were moderately energy deficient. Increased energy
availability did not result in increased energy expenditure at work, or in an
increased supply of work units. The results do not provide evidence of a strong
productive-energy intake relationship among these workers.

Müller ML , Coetsee MF (2008) Physiological demands and working

efficiency of sugarcane cutters in harvesting burnt and unburnt cane. Int J Ind
Ergonom 38(3–4):314–320Harvesting burnt and unburnt sugarcane has various
implications for the farmer and the cutters. The primary focus of this study was
to investigate in situ the differences in energy expenditure and working
efficiency of sugarcane cutters with regard to harvesting burnt and unburnt
sugarcane. Heart rate was measured telemetrically by means of a Polar Pacer
heart rate monitor. Metabolic measurements were done by means of the portable
MetaMax Ergospirometry System. Data per subject (n = 15) were collected on
two consecutive occasions, separated by at least 1 day, harvesting burnt and
unburnt cane. The short handle Okapi curved blade cane knife was used. After a
warm up period of 5 min to reach steady rate, data were collected for 30 min per
subject. Each day, four subjects were measured in the cane field between 05:00
and 09:00 h. Cane cutters used significantly more kilojoules (11.11%) and
worked at a higher percentage of their maximum aerobic capacity (11.96%)

9
while cutting unburnt as opposed to burnt cane. This was achieved with a
slightly higher (+3.23%) increase in mean heart rate. Ra tings of perceived
exertion (RPE) values recorded during harvesting burnt (11.71) and unburnt
(11.13) cane did not differ significantly. It was less cost effective (−24.22%) to
harvest unburnt cane as less cane was cut per time unit. Burnt cane required
significantly more cutting strokes per minute than unburnt cane.

Ma et al. (2012) Design and Experiment on Cleaning Leaves and

Breaking Tails Mechanism of Whole-stalk Sugarcane Harvester. A triangle
layout of the mechanism of cleaning leaves and breaking tails based on the
force analysis of motion of the sugarcane and its material properties was
presented. It successfully achieves the functions of raking and cleaning leaves,
and breaking tails. The orthogonal experiment on the self developed experiment
platform was carried out to verify the effect of the layout and find out the
optimal parameter combination. According to the experiment, the optimal
combination is: the rotating speed of the raking roller of 700 r/min, the speed of
the cleaning roller of 900 r/min, the interaction depth of the raking teeth of
40 mm, and the interaction depth of the cleaning element of 30 mm. The
experiment results show that the inverted goods font layout of the mechanism is
effective and feasible.

Luo et al. (2013) Tail-breaking Mechanism of Whole Stalk Sugarcane

Combine Harvester. The mechanical strength of rear end of sugarcane stalk is
significant lower than the middle and basal part. A tail-breaking mechanism was
designed. When the sugarcane stalk passing through this kind of mechanism,
the tails and 5~6 pieces of young leaves could be broken. Its working principle
was analyzed, and the orthogonal experiments were conducted to study the
influence between the following four factors: rotate speed of feeding and output
rollers, rotate speed of tail-breaking rollers, the centre distance between the top
and bottom tail-breaking rollers, and the relative installation position angle of

10
the top and bottom tail-breaking roller's elastic components. The result shows
that the optimal parameters were as following: rotate speed of feeding and
output rollers of 250 r/min, rotate speed of tail-breaking rollers of 550 r/min, the
centre distance between the top and bottom tail-breaking rollers of 300 mm, and
the relative installation position angle of the top and bottom tail-breaking
roller's elastic components of-20°. The best tail-broken rate in 4~6 sections
below the growth point of cane stalk reached to 63.3%. The average length of
these tails was 212 mm and standard deviation was 57 mm which meet the
agronomic requirements.

Liu et al. (2013) The Current Situation and Deliberation of Whole Stalk
Sugarcane Leaf-stripping Machine in Our Country. This paper contrastive
analyse of the sugarcane harvest mechanization status of each powers in the
world from the aspects of the key technology, industry benefit, combination of
farming machinery with agronomy technic. Combining with the production
condition of our country, aiming at the Whole-Stalk Sugarcane Leaves-
Stripping equipment, this paper analyse the research result of the predecessors,
and summarize the factors and their optimized results affecting the effect of
leaves stripping. At last, this paper put forward with the main problems still
exist, and provide advisory opinions to the later research of the Whole-Stalk
Sugarcane Leaves-Stripping equipment.

11
 CHAPTER 3
GENERAL MACHINE COMPONENTS AND SPECIFICATION
3.1 STEEL WIRE BRUSH
A wire brush is a tool consisting of a brush whose bristles are made of
wire, most often steel wire. The steel is generally a medium to high carbon
variety and very hard and springy. Other wire brushes feature bristles made
from brass or stainless steel, depending on application. Wires in a wire brush
can be held together by epoxy, staples, or other binding. Wire brushes usually
either have a handle of wood or plastic (for handheld use) are formed into a
wheel for use on angle grinders, bench grinders, pistol grip drill motors, or other
power tools. The wire brush is primarily an abrasive implement, used for
cleaning rust and removing paint. It is also used to clean surfaces and to create a
better conductive area for attaching electrical connections, such as those
between car battery posts and their connectors, should they accumulate a build-
up of grime and dirt. When cleaning stainless steel bristle wire brush, as a plain
carbon steel brush can contaminate the stainless steel and cause rust spots to
appear. Brass bristle brushes are used on softer surface or when it is necessary
to clean a harder surface without marring it. Brass bristle brushed are also used
in potentially flammable environments where non-sparking tools are required.
Wire brushes are also used to clean the teeth of large animals, such as
crocodiles and pigs. They are used widely in surface engineering to clean the
casting and paint the casting as shown in the Fig 3.1.

Fig 3.1 Steel wire Brush

12
3.2 USE OF WIRE BRUSH
Steel wire brushes are a tool fabricators use to finish different types of
metals. Brushes are used to remove flaking paint, rust, scratches, dirt and small
imperfections. They are used on concrete, metal, stone and wood surfaces. Wire
brush attachments are made for drills, grinders and other types of fabrication
tools.
They come in many different sizes, stiffness and wire types. Soft brushes
are used to bring out the luster and polish in a surface, while stiff brushes are
used for removing heavy debris.

Fig 3.2 Stainless Steel wire Brush

3.2.1 Dimension of Wire Brush
Table 3.1 Wire Brush Specifications
Outer diameter (do) 100 mm
Inner diameter (di) 17.4 mm
Width 20 mm
3.3 SELECTION OF MOTOR

We have selected sewing machine motor since the required torque for our
application needs 0.136 N.m. Which can be satisfied by single phase AC motor.

13
3.3.1 Motor
In electrical engineering, single-phase electric power is the distribution of
alternating current electric power using a system in which all the voltages of the
supply vary in unison. Single-phase distribution is used when loads are mostly
lighting and heating, with few large electric motors. Motor specifications are
shown in the Table 3.2
Table 3.2 Motor Specifications
Motor Type AC
Speed 7000 rpm
Shaft diameter 6 mm
Power developed 100 W
Voltage 220 V
3.4 BELT

The V-belt acts as a transmission belt. Connecting the V-belt pulleys, it

transmits the force from the engine to the ancillary components including the
alternator, the hydraulic pump for the power steering as shown in the Fig 3.3
.Belt specifications are shown in the Table 3.3

Table 3.3 Belt Specifications

Type V-Belt
Belt length 330 mm
Width 4 mm

14
 Fig.3.3 V-Belt section

3.5 PULLEY
A pulley is a wheel on an axle or shaft that is designed to support
movement and change of direction of a taut cable or belt, or transfer of power
between the shaft and cable or belt. In the case of a pulley supported by a frame
or shell that does not transfer power to a shaft, but is used to guide the cable or
exert a force, the supporting shell is called a block, and the pulley may be called
a sheave. The pulley is machined with mild steel
3.6 BEARING
A ball bearing is a type of rolling-element bearing that uses balls to
maintain the separation between the bearing races. The purpose of a ball bearing
is to reduce rotational friction and support radial and axial loads. It achieves this
by using at least three races to contain the balls and transmit the loads through
the balls. In most applications, one race is stationary and the other is attached to
the rotating assembly (e.g., a hub or shaft). As one of the bearing races rotates it
causes the balls to rotate as well. Because the balls are rolling they have a much
lower coefficient of friction than if two flat surfaces were sliding against each
other. Ball bearings tend to have lower load capacity for their size than other
kinds of rolling-element bearings due to the smaller contact area between the
balls and races. However, they can tolerate some misalignment of the inner and
outer races.

15
 Deep groove ball bearings are among the most widely used type of
bearing as shown in the Fig 3.4& 3.5. They can operate at high speeds and can
carry radial and (limited) axial loads. They are commonly used in electric
motors, compressors, fans, and conveyors

3.7 BENEFITS OF DEEP GROOVE BALL BEARING

Versatility - Because they can carry radial and axial loads, they have a
wider range of applications for many industries

Fig 3.4 Bearing 6203

Fig 3.5 Bearing 6204

Cost savings - Deep groove ball bearings create less friction torque. This
lowers operating temperature (which extends the life of the bearing) and
reduces energy cost of running equipment (such as conveyor belts).

16
 CHAPTER 4

FACTORS DETERMINING THE CHOICE OF MATERIALS

The various factors which determine the choice of material are discussed
below.
4.1 PROPERTIES
The material selected must possess the necessary properties for the
proposed application. The various requirements to be satisfied can be weight,
surface finish, rigidity, ability to withstand environmental attack from
chemicals, service life, reliability etc.

The following four types of principle properties of materials decisively

affect their selection. The factors are: Physical and ,Mechanical From
manufacturing point of view Chemical. The various physical properties
concerned are melting point, thermal conductivity, specific heat, coefficient of
thermal expansion, specific gravity, electrical conductivity, magnetic purposes
etc.

The various Mechanical properties Concerned are strength in tensile,

compressive shear, bending, torsional and buckling load, fatigue resistance,
impact resistance, elastic limit, endurance limit, and modulus of elasticity,
hardness, wear resistance and sliding properties.

The various properties concerned from the manufacturing point of view are:

 Cast ability
 Weld ability
 Surface properties
 Shrinkage
 Deep drawing etc.

17
4.2 MANUFACTURING CASE
Sometimes the demand for lowest possible manufacturing cost or surface
qualities obtainable by the application of suitable coating substances may
demand the use of special materials.

4.3 QUALITY REQUIRED

This generally affects the manufacturing process and ultimately the
material. For example, it would never be desirable to go casting of a less
number of components which can be fabricated much more economically by
welding or hand forging the steel.

4.4 AVAILABILITY OF MATERIAL

Some materials may be scarce or in short supply. It then becomes
obligatory for the designer to use some other material which though may not be
a perfect substitute for the material designed. The delivery of materials and the
delivery date of product should also be kept in mind.

4.5 SPACE CONSIDERATION

Sometimes high strength materials have to be selected because the forces
involved are high and space limitations are there.

4.6 COST
As in any other problem, in selection of material the cost of material
plays an important part and should not be ignored. Sometimes factors like scrap
utilization, appearance and non-maintenance of the designed part are involved
in the selection of proper materials.

18
 CHAPTER 5
DESIGN CALCULATIONS
5.1 CALCUALTION OF TORQUE
Torque is the turning force through a radius - with the units Nm in the SI-
system and the unit’s lb ft in the imperial system.
Maximum speed of the AC motor (N) = 7000 rpm
Power required by the motor (P) = 100 W
Maximum torque (Tmax) that can be developed by the AC motor is given by the
formula
P = (2*3.14 * N * Tmax)/60 (5.1)
Where,
P - Power developed by the motor
N - Speed of the motor
Tmax - Maximum torque developed
Tmax = (P*60)/2πN (5.2)
The motor can transmit a maximum torque of .136 Nm, which is much
more sufficient for our application.
5.2 CALCULATION OF CUTTING SPEED
Cutting speed is defined as the speed at the perimeter of the steel wire
brush, measured in meters per second. The higher the cutting speed, the higher
the dynamic brush hardness, which has a positive effect both on the life and the
stability of shape of the wire brush.
Outer diameter is the cutting perimeter of the circular wire brush
Outer diameter (do) = 100 mm
Speed of the brush (N) = 1017.09 rpm
Cutting speed of the brush is given by
Vc = ( do N)/1000 (5.3)
The obtained cutting speed of the wire brush 319.52 m/min

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The overall cutting speed of the machine is given by = Vc *L (5.4)
Where,
L - Machining length (40 mm)
Overall cutting speed = 12.78 m/min

5.3 CALCUALTION OF LENGTH OF THE BELT

The required center distance (C) = 144 mm
So, the length of the belt is given by,

L=2C + ( /2) (D+d) + ((D-d)2 /4)

Where,
Diameter of larger pulley (D) = 58.5 mm
Diameter of smaller pulley (d) = 8.5 mm
The overall length of the belt 315.25 mm

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 CHAPTER 6

WORKING PRINCIPLE
In this project we design sugarcane peeling machine. The machine
consists of belt drive arrangement with pulley and shaft containing the two steel
wire brush, and its operated by AC motor rotate at 7000 rpm. Here we run the
AC motor at 7000 rpm to transmit power by using belt drive to the shaft, then
the shaft rotate at 3500rpm with two wire brushes. We feed the sugarcane into
the bored space by manually and rotate it. Here the rotation of wire brush is to
peel the skin of the sugarcane and the process is continuous. The wire brush
arrangement is used to reduce the time consumption of peeling the sugarcane.
The speed of rotation of wire brush is varied by using a regulating pedal.

6.1 NEW DESIGN

Fig 6.1 New designs

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6.2 WHILE FUNCTIONING

Fig 6.2 while operating

6.3 MERITES
 Manufacturing cost is low
 Easy to handle the process
 Peeling time is less
 Less power consumption

6.4 DEMERITS
 Man power is required
 No backup charge at the time of power shutdown

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 CHAPTER 7
DRAFTING
7.1 PART DIAGRAM
Part diagram are the heart of any design or manufacturing new
component. When the part diagram is drafted accurately, the machining process
will become easy. The reductions in raw material are calculated from the overall
size of the component to be manufactured. Unless the correct shape and quality
of the raw material is not chosen, the efficiency of the production will decline
and more material is wasted.

Refer: Appendix

7.2 ASSEMBLY DIAGRAM

The position and mating parts of various components are referred from
assembly diagram. Sub assembly are used when the there is a complex
component consisting of more than 2 parts. As shown is the Fig 7.1.

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Fig 7.1

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 CHAPTER 8
COST ESTIMATION
Table 8.1 Project estimation

SI. No Particular Total No. Required Cost(Rs.)

1 Motor & regulator 1 700
2 V Belt 1 20
3 Motor plate 1 50
4 Driver Pulley 1 20
5 Driven pulley 1 150
6 Wire Brush 2 200
7 6203 Bearing 1 60
8 6204 Bearing 1 50
9 Main shaft 1 100
10 16mm Plate 2 200
11 10mm Plate 2 172
12 M6 Allen 4 20
13 M6 Bolt & Nut 6 20
14 Wood screw 2 10
15 Central Block 1 30
16 Base Board 1 120
17 Labour charge - 1000

Total cost of project 2922.00

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 CHAPTER 9
CONCLUSION
This model provides a solution for complicated problem faced in peeling
sugarcane. By this mechanical prototype the manual work is made easier in a
much cost efficient way. With this simple and efficient design user can
dismantle the components easily for cleaning purpose. As all the material used
in our project are non corrosive. It is highly hygienic when compared with other
peeling machine. The smooth running of the shaft is achieved by using deep
groove ball bearing. The future development of the project will add additional
features of a cutter and a feeder.

26
 REFERENCES

1. Immink MDC, Viteri FE (1981) Energy intake and productivity of

Guatemalan sugarcane cutters: An empirical test of the efficiency wage
hypothesis part I. J Dev Econ vol. 9.,pp. 251–271.
2. Müller ML, Coetzee MF (2008) Physiological demands and working
efficiency of sugarcane cutters in harvesting burnt and unburnt cane. Int J
Ind Ergonom vol. 38.,pp 314–320.
3. Ma et al. (2012) Design and Experiment on Cleaning Leaves and
Breaking Tails Mechanism of Whole-stalk Sugarcane Harvester.
4. Luo et al. (2013) Tail-breaking Mechanism of Whole Stalk Sugarcane
Combine Harvester.
5. Liu et al. (2013) The Current Situation and Deliberation of Whole Stalk
Sugarcane Leaf-stripping Machine.
6. Li Y, Zheng G, Song Y, Zhang T, Wu Y (2010) Experiment and
Research on Small-sized Sugarcane Leaf Stripping Machine. Equip
Manuf Technol.

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APPENDIX

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