DESIGN AND FABRICATION OF

MECHANICAL SICKLE

A MINI PROJECT REPORT

Submitted by

AJAY V (AC16UME007)

ANTO P (AC16UME014)

ARAVIND V (AC16UME015)

ARUN KUMAR K (AC16UME021)

In partial fulfilment for the award of the degree

of

BACHELOR OF ENGINEERING

in
DEPARTMENT OF MECHANICAL ENGINEERING

ADHIYAMAAN COLLEGE OF ENGINEERING, HOSUR

(AUTONOMOUS)
(Accredited by NBA- AICTE, New Delhi, Accredited by NAAC- UGC,

New Delhi with ‘A’ Grade)

ANNA UNIVERSITY: CHENNAI – 600 025

 BONAFIDE CERTIFICATE
This is to certify that the mini project entitled “DESIGN AND
FABRICATION OF MECHANICAL SICKLE” is the bonafied record of the
project work done by AJAY V , ANTO P , ARAVIND V , ARUN KUMAR K,
of final year department of mechanical engineering during the year 2019-2020.

SIGNATURE SIGNATURE
Dr.SURESH BABU, M.E, Ph.D., M.PARTHIBAN, M.E.,
PROFESSOR & HEAD, ASSOCIATE PROFESSOR,
Department of Mechanical Engineering, Department of Mechanical Engineering,
Adhiyamaan College of Engineering Adhiyamaan College of Engineering
(Autonomous), (Autonomous),
Dr.M.G.R Nagar, Hosur-635130 Dr.M.G.R Nagar, Hosur-635130

Submitted for project viva-voce Examination held on................................at

Adhiyamaan College Of Engineering (Autonomous), Hosur.

INTERNAL EXAMINER EXTERNAL EXAMINER

 ACKNOWLEDGEMENT

Our first and the foremost gratitude to almighty and our parents who
showered the blessing and gave us the knowledge and strength to perform our work
& also in ADHIYAMAAN COLLEGE OF ENGINEERING that gives me an
opportunity to have sound based knowledge MECHANICAL ENGINEERING.

We express our sincere thanks to our honourable Principal

DR.G.RANGANATH, M.E.,Ph.d., Adhiyamaan College Of Engineering for
generously providing us with excellent facilities throughout the course of study and
especially for this project.

We owe our deep sense and profound gratitude to be Head of the Mechanical
Department DR.SURESH BABU, M.E.,P.hd., Adhiyamaan College Of
Engineering for his through put provoking, painstaking guidance and supervision
at every stage of our study.

We thankfully acknowledge the abiding interest of our project guide

Mr.M.PARTHIBAN, M.E., Assistant Professor, Department of Mechanical
engineering, Adhiyamaan College Of Engineering who took this project upon him
in all status and worked very closely with all members of our project.

We also express our hearty thanks to all our staff members of Department of
Mechanical for their encouragement and support to complete the project work
successfully.

Finally our acknowledgement goes to all our parents and friends who had
extended their excellent support and ideas to make our project a pledge one.
 ABSTRACT

In our project we design and fabricate the motorized mechanical sickle for
the use of agricultural field, to cut the crops in the field. It is simple in design and
cost efficient. This is a new innovative concept mainly used in agricultural field.
It is simple in construction and its working is easy. The components that are used
are motor, blade arrangement, and lead screw, battery, wheel, control unit.

When the motor starts running by the use of power supply, the shaft also
rotates and that rotates the solid arrangement which is coupled with the motor. It
operates the sickle bar which tends to cut the plants or crops. The sickle bar has
one is fixed cutter and another one is movable cutter which is placed on it. The
whole set up is placed on a movable base which has a wheel arrangement. Where
the lower cutter blade has more teeth and also it was fixed with the base frame.
The upper cutter blade reciprocates itself above the lower blade. The solid
arrangement helps to convert the rotary motion from the motor shaft to the
reciprocating motion that runs the cutter. The power supply is given from the
battery.
 TABLE OF CONTENT

CHAPTER NO. TITLE PAGE NO.

ABSTRACT

LIST OF TABLE

LIST OF FIGURES

LIST OF SYMBOLS

1 INTRODUCTION

1.1 INTRODUCTION TO THE PROJECT

1.2 OBJECTIVE OF THE PROJECT

2 LITERATURE SURVEY

2.1 LAWN MOWER

2.2 MOWER AND ITS TYPES

2.3 REVIEW OF JOURNALS

3 PROJECT DESCRIPTION

3.1 COMPONENTS OF THE PROJECT

3.1.1 DC MOTOR

3.1.2 BLADE

3.1.3 SHAFT

3.1.4 BEARING
 3.1.5 ROLLER

3.1.6 FRAME

3.2 METHODOLGY

4 DESIGN CALCULATION

4.1 MOTOR CALCULATION

4.2 TORQUE CALCULATION

4.3 CUTTING SPEED

4.4 FEED PER CUTTING

4.5 DESIGN CALCULATION OF BALL

BEARING
5 FABRICATION PROCESS

5.1 TYPES OF MACHINING PROCESS

5.1.1 CUTTING

5.1.2 WELDING

5.1.3 DRILLING

5.2 MATERIAL USED

5.3 COST ESTIMATION

5.4 ADVANTAGES AND APPLICATION

6 CONCLUSION & REFERENCE

 LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1.1 LAWN MOWER

2.1 ROTARY MOVER

2.2 REEL MOVER

2.3 FLAIL MOVER

3.1 DC MOTOR

3.2 ARMATURE

3.3 SHAFT

3.4 BALL BEARING

3.5 PARTS OF BALL BEARING

3.6 FRAME

3.7 MS FRAME

5.1 CIRCULAR SAW BLADE

5.2 SAW MACHINE

5.3 WELD PART

5.4 WELDING OPERATION

5.5 RADIAL DRILLING MACHINE

 LIST OF SYMBOLS

SYMBOLS DESCRIPTION UNIT

N SPEED RPM

T TORQUE N-mm

d DIAMETER mm

P POWER W

𝜔 ANGULAR VELOCITY Rad/sec

Vc CUTTING SPEED m/s

Fz FEED PER CUTTING mm

dm DIAMETER OF BALL BEARING mm

 CHAPTER 1

INTRODUCTION

1.1 INTRODUCTION OF THE PROJECT

A sickle bagging hook or reaping hook is a held agricultural tool designed

with variously curved blades and typically used for harvesting, or
reaping, grain crops or cutting succulent forage chiefly for feeding livestock, either
freshly cut or dried as hay.

The mechanical sickle is used to cut the crops mechanically using motor .In
our mechanical sickle there has a vertical rotor shaft has many pairs of swinging
knives that cut the crops at equal height. These cutting takes place due to impact
and shearing action.

Crop harvesting is last stage in farming which takes maximum time of farmer
among all farming Process. In India harvesting is generally done manually. In our
country it is generally done by sharp sickle. This machine consist of simple
Mechanism make to run by a DC motor which will be economical to farmer and
will take less time for harvesting operation.

On the basis of large no. of this crop harvester are in use at today’s date,
which are available at different shape and size and on different power supply. Since
they are costlier keeping in to consideration the economic ability of our farmer it is
required that is should be simple and should fulfill the same intension which are
achieved by “MOTORIZED MECHANICAL SICKLE”.

1.2 OBJECTIVE OF THE PROJECT

The main objective is to design and fabricate the motorized mechanical

sickle.
 CHAPTER 2

LITERATURE REVIEW

2.1 LAWN MOWER

A lawn mower (also named as mower, grass cutter or lawnmower) is a

machine utilizing one or more revolving blades to cut a grass surface to an even
height. The height of the cut grass may be fixed by the design of the mower, but
generally is adjustable by the operator, typically by a single master lever, or by a
lever or nut and bolt on each of the machine's wheels. The blades may be powered
by manual force, with wheels mechanically connected to the cutting blades so
that when the mower is pushed forward, the blades spin, or the machine may have
a battery-powered or plug-in electric motor. The most common self-contained
power source for lawn mowers is a small (typically one cylinder) internal
combustion engine.

FIG 2.1 LAWN MOWER

 Smaller mowers often lack any form of propulsion, requiring human power
to move over a surface; "walk-behind" mowers are self-propelled, requiring a
human only to walk behind and guide them. Larger lawn mowers are usually
either self-propelled "walk-behind" types, or more often, are "ride-on" mowers,
equipped so the operator can ride on the mower and control it. A robotic lawn
mower ("lawn-mowing bot", "mowbot", etc.) is designed to operate either
entirely on its own, or less commonly by an operator by remote control.

Two main styles of blades are used in lawn mowers. Lawn mowers
employing a single blade that rotates about a single vertical axis are known as
rotary mowers, while those employing a cutting bar and multiple blade assembly
that rotates about a single horizontal axis are known as cylinder or reel mowers
(although in some versions, the cutting bar is the only blade, and the rotating
assembly consists of flat metal pieces which force the blades of grass against the
sharp cutting bar).

There are several types of mowers, each suited to a particular scale and
purpose. The smallest types, non-powered push mowers, are suitable for small
residential lawns and gardens. Electrical or piston engine-powered push-mowers
are used for larger residential lawns (although there is some overlap). Riding
mowers, which sometimes resemble small tractors, are larger than push mowers
and are suitable for large lawns, although commercial riding lawn mowers (such
as zero-turn mowers) can be "stand-on" types.

Then often bear little resemblance to residential lawn tractors, being

designed to mow large areas at high speed in the shortest time possible. The
largest multi-gang (multi-blade) mowers are mounted on tractors and are
designed for large expanses of grass such as golf courses and municipal parks,
although they are ill-suited for complex terrain.
2.2 MOWER AND IT TYPES

Sickle mowers, also called reciprocating mowers, bar mowers, sickle-bar

mowers, or finger-bar mowers, have a long (typically six to seven and a half feet)
bar on which are mounted fingers with stationary guardplates. In a channel on the
bar there is a reciprocating sickle with very sharp sickle sections (triangular
blades). The sickle bar is driven back and forth along the channel. The grass, or
other plant matter, is cut between the sharp edges of the sickle sections and the
finger-plates (this action can be likened to an electric hair clipper).

The bar rides on the ground, supported on a skid at the inner end, and it can
be tilted to adjust the height of the cut. A spring-loaded board at the outer end of
the bar guides the cut hay away from the uncut hay. The so-formed channel,
between cut and uncut material, allows the mower skid to ride in the channel and
cut only uncut grass cleanly on the next swath. These were the first successful
horse-drawn mowers on farms and the general principles still guide the design of
modern mowers.

2.2.1 ROTARY MOWER

Rotary mowers, also called drum mowers, have a rapidly rotating bar, or
disks mounted on a bar, with sharpened edges that cut the crop. When these
mowers are tractor-mounted they are easily capable of mowing grass at up to 20
miles per hour (32 km/h) in good conditions.

FIG 2.2 ROTARY MOWER

In rough cutting conditions, the blades attached to the disks are swivelled to
absorb blows from obstructions. Mostly these are rear-mounted units and in some
countries are called scrub cutters. Self-powered mowers of this type are used for
rougher grass in gardening and other land maintenance

2.2.2 REEL MOWER

Reel mowers, also called cylinder mowers (familiar as the hand-pushed or

self-powered cylinder lawn mower), have a horizontally rotating cylindrical reel
composed of helical blades, each of which in turn runs past a horizontal cutter-
bar, producing a continuous scissor action. The bar is held at an adjustable level
just above the ground and the reel runs at a speed dependent on the forward
movement speed of the machine, driven by wheels running on the ground). The
cut grass may be gathered in a collection bin.

FIG 2.3 REEL MOWER

This type of mower is used to produce consistently short and even grass on
bowling greens, lawns, parks and sports grounds. When pulled by a tractor (or
formerly by a horse), these mowers are often ganged into sets of three, five or
more, to form a gang mower. A well-designed reel mower can cut quite tangled
and thick tall grass, but this type works best on fairly short, upright vegetation, as
taller vegetation tends to be rolled flat rather than cut.
 Home reel mowers have certain benefits over motor-powered mowers as
they are quieter and not dependent on any extra form of power besides the person
doing the mowing. This is useful not only to lessen dependence on other types of
power which may have availability issues, but also lessens the impact on the
environment.

2.2.3 FLAIL MOWER

Flail mowers have a number of small blades on the end of chains attached
to a horizontal axis. The cutting is carried out by the ax-like heads striking the
grass at speed. These types are used on rough ground, where the blades may
frequently be fouled by other objects, or on tougher vegetation than grass, such
as brush (scrub).

FIG 2.4 FLAIL MOWER

Due to the length of the chains and the higher weight of the blades, they
are better at cutting thick brush than other mowers, because of the relatively high
inertia of the blades. In some types the cut material may be gathered in a
collection bin. As a boom mower (see above), a flail mower may be used in an
upright position for trimming the sides of hedges, when it is often called a hedge-
cutter.

2.2.4 DRUM MOWER

Drum mowers have their horizontally-mounted cutting blades attached to

the outside of a relatively large diameter disc fixed to the bottom of a smaller
diameter drum and are principally designed for cutting lighter crops, such as
grass, very quickly. The drive mechanism is top-mounted and often in the form
of fully enclosed, bevel geared drive shafts

2.3 REVIEW OF JOURNALS

2.3.1 DESIGN AND FABRICATION ANALYSIS OF LAWN MOWER

VENKATESH.K, PRIYANKA K, SRIDHAR R , SAKTHIVEL A

The first lawn mower (grass cutter) was invented by Edwin Budding in
1827 in Stroud, Gloucestershire. Budding's mower was designed primarily to cut
the lawn on sports grounds and expensive gardens, as a superior alternative to the
scythe, and was patented in 1830. It took ten more years and further innovations
to create a machine that could be worked by animals, and sixty years before a
steam-powered lawn mower was built. In an agreement between John Ferrabee
and Edwin Budding dated May 18, 1830, Ferrabee paid the costs of development,
obtained letters of patent and acquired rights to manufacture, sell and license
other manufacturers in the production of lawn mowers. Thomas Green produced
the first chain-driven mower in 1859.

The grass cutter for cutting the grass in the field. It consists of simple manner
and the using components are motor, cam, chain and sprocket, lead screw,
wheel, cutter. Arrangement witch this project using two cutter one movable
cutter another one fixed cutter the movable cutter is connecting to the cam link
and cam is rotating help of motor. Here the motor is working using with the
help of electric power supply; When the motor to start running the shaft is rotate
and it’s rotating the cam arrangement is rotating with attach of cutting blade
and the cutting process is carrying out by this machine. The grass cutter vehicle
is moving help of motor. The motor is connecting with the chain and sprocket
arranges meant the pulley is coupled with wheel shaft.
2.3.2 DESIGN AND FABRICATION OF ENGINE POWERED
MECHANICAL SICKLE

GOUKUL M, MADESHA L, RAGUPATHI V, RAJA M, SAJITH KUMAR S

Farrabee's company was making eight models in various roller
sizes. He manufactured over 5000 machines until production ceased in
1863. In 1870, Elwood McGuire of Richmond, Indiana designed a
human-pushed lawn mower, which was very lightweight and a
commercial success. John Burr patented an improved rotary-blade
lawn mower in 1899, with the wheel placement altered for better
performance. Amariah Hills went on to found the Archimedean Lawn
Mower Co. in 1871. Around 1900, one of the best known English
machines was the Ransomes' Automaton, available in chain- or gear-
driven models. JP Engineering of Leicester, founded after World War
I, produced a range of very popular chain driven mowers. About this
time, an operator could ride behind animals that pulled the large
machines. These were the first riding mowers.

Machine performs mainly three operations cutting, collecting and

bunching of the crops. The engine is mounted on the frame using nut and bolts.
With the help of chain drive, Engine and input shaft of bevel gear box is
connected. The output shaft of the bevel gearbox is connected to collecting
mechanism using belt pulley system and the other end connected to the cutting
mechanism using crank shaft system. We are using a single knife reciprocating
cutter whose one blade is moving and other is stationary. The slider crank used
to convert rotary to reciprocating motion for cutter. Scissoring action is
obtained due to reciprocating movement
2.3.3 DESIGN AND FABRICATION OF GRASS CUTTER

MAHESH PANDE, PRATIK KUDUSE, MILIND PETHKAR, LUKESH

MANUSMARE

Grass cutter machines have become very popular today. Most common
machines are used for soft grass furnishing. In our project Grass cutter machine
we are aimed to develop for operation and construction. Agriculture is the most
important sector in the Indian economy. In India there is a great scope of grass
cutter machine. In our country as well as other countries has also it is used in
various fields for cutting the grass. The machine may consist of two, three or
four blades depending upon the machine. The grass cutting machine is known
as lawn mower. The grass cutting machine is available in the various types like
reel (cylinder) mower, rotary and mulching mower, hover mower, riding
mower, professional mower etc.
The machines required for manufacturing includes welding machine,
grinding machine etc. Working principle of the grass cutter is providing a high
speed rotation to the blade, which helps to cut the grass. The blade will get
kinetic energy while increasing the rpm. The cutting edges are very smooth and
accurate. Also Electric Grass Cutting Machines are much easier to be used in
garden, lawn and grass fields. In order to enhance the beauty of home-lawns and
gardens, Grass cutting machines are the best available option in the industry.

2.3.4 DESIGN AND FABRICATION OF COMMERCIAL GRASS

CUTTING AND COLLECTING MACHINE
AAQIB GULZAR KHAN, ADEEL-UL-HAQ QURISHI
The conventional grass cutting machines that are employed for cutting the
grass in the fields have the disadvantage that during the cutting of the grass the
grass gets scattered around the machine due to the strong cutting forces hence
requiring further labor to collect it. The new machines that collect the grass
during cutting have the disadvantage that they can cut and collect only short
grass not more than 8-10 inches long. Till date the long commercial grass which
is usually more than 4 feet long is reaped manually like paddy using a sickle.
This method is very laborious and unproductive and hence there was a need to
improve the scenario. The new grass cutter is specially designed for the
reaping/harvesting of the commercial grass resulting in less fatigue to workers
and increasing the productivity.
The most important part is the horizontal grass collector. It is actually a
horizontal plate located just above the blades that sweeps across the blades after
every single rotation of wheels. This motion is controlled by the sensor that is
activated after every wheel rotation, and sends a pulse to an electric motor which
is connected to the horizontal plate via the rack and pinion mechanism. For every
pulse, the motor moves clock wise and counter clock wise for 200ms, enabling
the horizontal blade to move to and fro across the blades in 200ms. The electric
current for the sensor and the motor is derived from the alternator attached to
the engine kit.

2.3.5 DESIGN AND FABRICATION OF TWO WHEELER OPERATED

SICKLE BAR MOWER
SHEIKH MOHAMMAD MUSHEERUDDIN M, PROF. K. I. AHMED
There are three main methods of harvesting using manual labor, harvesting
by mowers, and harvesting by silage machines. Scythe is mostly used in manual
cutting of grass, but this is suitable for small lawns. In second method we
observed that for large are ie. (>200m2 area) tractor two behind mower or riding
mower is used, but the biggest disadvantage of the tractor- mounted type mower
is dependency and availability of a tractor .
For these reasons, a tow-behind Sickle bar mower was selected for
exploring its adaptability to overcome problems in terms of cost and versatility
on various small- scale enterprises. In this project we designed and fabricate
tow-behind type mover. Tow-behind mowers are used for much larger areas,
like massive fields, large lawn, yards, play ground and are used much more in
agriculture and road sides . Two-wheeler tows these sickle bar mechanism and
provide power to mechanism. And cut the hay (grass) shrubs. Basic components
are sickle bar, cutting blades; drive system, cam, wheels, etc.

CHAPTER 3

PROJECT DESCRIPTION

3.1 COMPONENTS OF THE PROJECT

1.DC MOTOR

2.BLADE

3.SHAFT

4.BEARING

5.ROLLER

6.FRAME

3.1.1 DC Motor

According to Faraday’s law, which states that “an emf induced in any
closed circuit is due to the rate of change of magnetic flux through the circuit”,
Emf is induced in the Copper bar and due to this, current flows in the rotor. The
direction of the rotor can be given by Lenz law which states that – “the direction
of induced current will be in the opposite of the motion causing it.”

Here the relative velocity between the rotating flux and static rotor
conductor is the cause of current generation; hence the rotor will rotate in the
same direction to reduce the cause i.e. the relative velocity, thus rotating
the rotor of the induction motor.
 FIG 3.1 DC MOTOR

A DC motor is any of a class of rotary electrical machines that converts

direct current electrical energy into mechanical energy. The most common types
rely on the forces produced by magnetic fields. Nearly all types of DC motors
have some internal mechanism, either electromechanical or electronic, to
periodically change the direction of current flow in part of the motor.

DC motors were the first form of motor widely used, as they could be
powered from existing direct-current lighting power distribution systems. A DC
motor's speed can be controlled over a wide range, using either a variable supply
voltage or by changing the strength of current in its field windings. Small DC
motors are used in tools, toys, and appliances. The universal motor can operate
on direct current but is a lightweight brushed motor used for portable power tools
and appliances. Larger DC motors are currently used in propulsion of electric
vehicles, elevator and hoists, and in drives for steel rolling mills. The advent of
power electronics has made replacement of DC motors with AC motors possible
in many applications.
 FIG 3.2 ARMATURE

3.1.2 BLADE

Mower blades are the cutting components of lawn mowers. They are
usually made of sturdy metals as they must be able to withstand high-speed
contact with a variety of objects in addition to grass. The materials used (as well
as size, thickness, and design of the blades) vary by manufacturer.

TYPES OF MOVER BLADES

1.REEL OR CYLINDER BLADES

Used in reel or cylinder mowers, cylinder blades are composed of

three to seven helical blades welded in a horizontally rotating cylindrical
reel, creating a scissor-like cutting action. Unlike other types of mower
blades, reel/cylinder blades cannot be replaced; therefore, a broken blade
requires replacement of the entire mower. For dull or rusty blades, cleaning
and sharpening kits are available.

2.DECK BLADES

Also known as the standard or straight mower blade, this is the most
commonly used blade on rotary mowers.

3.MULCHING BLADES
 A mulching blade, also known as an all-purpose blade, features a
curved surface which allows it to work in three ways: lifting, mowing, and
mulching. First, the blade pulls the grass up and cuts it. Then, clippings are
sucked inside the deck and are chopped into tinier pieces. Finally, the
blade’s innermost curve produces air pressure to blow the small clippings
out, where they are used to feed the soil.

4.LIFTING BLADES

The lifting blade features a slightly curved surface which creates a

vertical upward airflow that lifts the grass up and is assumed to provide a
cleaner result than the other types of blades.

Low-lift blade

Low suction power; recommended for mowing terrain with sandy

soil.

Medium-lift blade

Medium suction power; uses less horsepower than high-lift blades.

High-lift blade

Provides the greatest suction power among the three lifting blades,
but also requires the most horsepower. This is the best blade for cutting
tall, compact grass

3.1.3 SHAFT

Power transmission between two rotating components requires a secure

connection between the shaft of the driving component, and the hub of the
mating part. One way to ensure torque transmission without slipping is by using
a keyed connection. For most automation applications (motors, gearboxes,
pulleys, etc.), a parallel key, also known as a straight key, with a square cross-
section is used.

FIG 3.3 SHAFT

Keyed connections, however, do have a drawback—they require a

reduction in shaft diameter of the torque-transmitting component. And of
the smaller the diameter, the less torque can be transmitted before failure
occurs. To demonstrate, below is an example of the maximum torque that
can be transmitted by a keyless shaft, compared with the torque that can be
transmitted by the same shaft when a key (per DIN 6885) is added.

3.1.4 BEARING

A bearing is a machine element that constrains relative movement to the

desired motion and reduces friction between moving parts. The design of the
bearing may, for example, provide for free linear movement of the moving part
or for free rotation around a fixed axis; or, it may prevent a motion by controlling
the vectors of normal forces that bear on the moving parts.

Most bearings facilitate the desired motion by minimizing friction.

Bearings are classified broadly according to the type of operation, the motions
allowed, or to the directions of the loads (forces) applied to the parts.

Rotary bearings hold rotating components such as shafts or axles within

mechanical systems, and transfer axial and radial loads from the source of the
load to the structure supporting it. The simplest form of bearing, the plain bearing,
consists of a shaft rotating in a hole. Lubrication is used to reduce friction. In
the ball bearing and roller bearing, to reduce sliding friction, rolling elements
such as rollers or balls with a circular cross-section are located between the races
or journals of the bearing assembly.

A wide variety of bearing designs exists to allow the demands of the

application to be correctly met for maximum efficiency, reliability, durability and
performance.

The term "bearing" is derived from the verb "to bear" a bearing being a
machine element that allows one part to support another. The simplest bearings
are bearing surfaces, cut or formed into a part, with varying degrees of control
over the form, size, roughness and location of the surface. Other bearings are
separate devices installed into a machine or machine part. The most sophisticated
bearings for the most demanding applications are very precise devices; their
manufacture requires some of the highest standards of current technology.

FIG 3.4 BALL BEARING

3.1.4.1 TYPES OF BEARING

There are at least 6 common types of bearing, each of which operates on

different principles:
 Plain bearing, consisting of a shaft rotating in a hole. There are several
specific styles: bushing, journal bearing, sleeve bearing, rifle
bearing, composite bearing;

 Rolling-element bearing, in which rolling elements placed between the

turning and stationary races prevent sliding friction. There are two main
types:

o Ball bearing, in which the rolling elements are spherical balls;

o Roller bearing, in which the rolling elements are cylindrical, taper

and spherical rollers;

 Jewel bearing, a plain bearing in which one of the bearing surfaces is made
of an ultrahard glassy jewel material such as sapphire to reduce friction and
wear;

 Fluid bearing, a noncontact bearing in which the load is supported by a gas

or liquid (i.e. air bearing).

 Magnetic bearing, in which the load is supported by a magnetic field;

 Flexure bearing, in which the motion is supported by a load element which

bends.
 FIG 3.5 PARTS OF BEARING

3.1.4.2 FRICTION OF BEARING

Reducing friction in bearings is often important for efficiency, to reduce

wear and to facilitate extended use at high speeds and to avoid overheating and
premature failure of the bearing. Essentially, a bearing can reduce friction by
virtue of its shape, by its material, or by introducing and containing a fluid
between surfaces or by separating the surfaces with an electromagnetic field.

 By shape: gains advantage usually by using spheres or rollers, or by forming

flexure bearings.
 By material: exploits the nature of the bearing material used. (An example
would be using plastics that have low surface friction.)
 By fluid: exploits the low viscosity of a layer of fluid, such as a lubricant or
as a pressurized medium to keep the two solid parts from touching, or by
reducing the normal force between them.
 By fields: exploits electromagnetic fields, such as magnetic fields, to keep
solid parts from touching.
 Air pressure: exploits air pressure to keep solid parts from touching.
3.1.5 ROLLERS

A roller mower, or roller mower, is a tractor-powered multi-

spindled rotary mowers that have full width rollers front and rear. Most roller
mowers attach to a four-wheeled tractor via the three-point linkage and are
powered by the tractor’s power take-off (PTO), though larger models connect
three or more complete mowing decks to a separate chassis that is towed behind
the tractor. Good roller mowers can produce a finish rivalling that of reel
(cylinder) mowers while generally being far more robust and requiring
considerably less maintenance. Modern machines can also cope efficiently with
a wider range of grass lengths and densities than cylinder mowers.

3.1.6 FRAME

The metal frame is generally made of mild steel bars for machining,
suitable for lightly stressed components including studs, bolts, gears and shafts.
It can be case-hardened to improve wear resistance. They are available in bright
rounds, squares and flats, and hot rolled rounds. Bright steel can also be obtained
in precision turned or ground form if desired.

FIG 3.6 FRAME

 Suitable machining allowances should therefore be added when ordering.
It does not contain any additions for enhancing mechanical or machining
properties. Bright drawn mild steel is an improved quality material, free of scale,
and has been cold worked (drawn or rolled) to size. It is produced to close
dimensional tolerances. Straightness and flatness are better than black steel. It is
more suitable for repetition precision machining

A hollow structural section (HSS) is a type of metal profile with a

hollow cross section. The term is used predominantly in the United States, or
other countries which follow US construction or engineering terminology. HSS
members can be circular, square, or rectangular sections, although other shapes
such as elliptical are also available. HSS is only composed of structural steel per
code. HSS is sometimes mistakenly referenced as hollow structural steel.
Rectangular and square HSS are also commonly called tube steel or box section.

FIG 3.7 MS FRAME

Circular HSS are sometimes mistakenly called steel pipe, although true
steel pipe is actually dimensioned and classed differently from HSS. (HSS
dimensions are based on exterior dimensions of the profile; pipes are also
manufactured to an exterior tolerance, albeit to a different standard.) The corners
of HSS are heavily rounded, having a radius which is approximately twice the
wall thickness. The wall thickness is uniform around the section.

3.2 METHODOLGY

LITRATURE REVIEW

MATERIAL SELECTION

DESIGN CALCULATION

FABRICATION

CONCLUSION

CHAPTER 4

DESIGN CALCULATION

4.1 MOTOR CALCULATION

Motor Speed , N = 300 rpm

Voltage, V = 12 volts

Current , I = 0.3 amps

Power input = V×I

 P =12×0.3

P = 3.6 watts

4.2 TORQUE CALCULATION

Output power ,Pout = T×𝜔

Angular Velocity, 𝜔= N×2π/60

= 300×2π/60

𝜔 = 31.41 rad/s

E = Output power / Input power

E = Pout/Pin

Pout = Pin ×E

T×𝜔= I×V×E

T = I×V×E / 𝜔

= 0.3×12×36 / 31.4

= 4.12Nm

T = 4120 N mm

4.3 CUTTING SPEED

Vc= 𝜋𝑑𝑛/60
=𝜋*12*300/60
Vc = 0.188 m/min
4.4 FEED FOR CUTTING

Fz=Vc/n*z
=0.188/(300*1)
Fz = 0.62mm

4.5 DESIGN OF BALL BEARING

Bearing No. 6202 (Data book page.no 4.13)

Outer Diameter of Bearing (D) = 37 mm

Thickness of Bearing (B) = 12 mm

Inner Diameter of Bearing (d) = 15 mm

r₁ = Corner radii on shaft and housing

r₁ = 1(From design data book)

Maximum Speed = 14,000 rpm (From design data book)

Mean Diameter (dm) = (D + d) / 2

= (37 + 15) / 2

dm = 26 mm

CHAPTER 5

FABRICATION PROCESS

Manufacturing processes are the steps through which raw materials are
transformed into a final product. The manufacturing process begins with the
creation of the materials from which the design is made. These materials are then
modified through manufacturing processes to become the required part.
Manufacturing processes can include treating (such as heat treating or coating),
machining, or reshaping the material. The manufacturing process also includes
tests and checks for quality assurance during or after the manufacturing, and
planning the production process prior to manufacturing.

5.1 TYPES OF MACHINIG PROCESS

5.1.1 CUTTING

A circular saw is a power-saw using a toothed or abrasive disc or blade to

cut different materials using a rotary motion spinning around an arbor. A hole
saw and ring saw also use a rotary motion but are different from a circular
saw. Circular saws may also be loosely used for the blade itself. Circular saws
were invented in the late 18th century and were in common use in sawmills in the
United States by the middle of the 19th century.

FIG 5.1 CIRCULAR SAW BLADE

A circular saw is a tool for cutting many materials such

as wood, masonry, plastic, or metal and may be hand-held or mounted to a
machine. In woodworking the term "circular saw" refers specifically to the hand-
held type and the table saw and chop saw are other common forms of circular
saws. "Skilsaw" and "Stihl saw" have become generic trademarks for
conventional hand-held circular saws

. Circular saw blades are specially designed for each particular material
they are intended to cut and in cutting wood are specifically designed for
making rip-cuts, cross-cuts, or a combination of both. Circular saws are
commonly powered by electricity, but may be powered by a gasoline engine or
a hydraulic motor which allows it to be fastened to heavy equipment, eliminating
the need for a separate energy source. Originally, circular saws in mills had
smaller blades and were used to resaw lumber after it passed through an "up and
down" (muley or sash) saw leaving both vertical and circular saw marks on
different sides of the same piece.

FIG 5.2 SAW MACHINE

 These saws made it more efficient to cut small pieces such as lath. After
1813 or 1822 saw mills use large circular saws, up to 3 meters (9 ft) in diameter.
Large saws demand more power than up-and-down saws and did not become
practical for sawing timbers until they were powered by steam engines. They are
either left or right-handed, depending on which side of the blade the plank falls
away from. Benching determines which hand the saw is.

Saws of this size typically have a shear pin hole, off axis, that breaks if the
saw is overloaded and allows the saw to spin free. The most common version is
the ITCO (insert tooth cut-off) which has replaceable teeth. Sawmill blades are
also used as an alternative to a radial arm saw.

5.1.2 WELDING

Arc welding is a welding process that is used to join metal to metal by

using electricity to create enough heat to melt metal, and the melted metals when
cool result in a binding of the metals. It is a type of welding that uses a welding
power supply to create an electric arc between a metal stick ("electrode") and the
base material to melt the metals at the point of contact. Arc welders can use
either direct (DC) or alternating (AC) current, and consumable or non-
consumable electrodes.
 FIG 5.3 WELD PART

The welding area is usually protected by some type of shielding gas, vapor,
or slag. Arc welding processes may be manual, semi-automatic, or fully
automated. First developed in the late part of the 19th century, arc welding
became commercially important in shipbuilding during the Second World War.
Today it remains an important process for the fabrication of steel structures and
vehicles.

To supply the electrical energy necessary for arc welding processes, a

number of different power supplies can be used. The most common classification
is constant current power supplies and constant voltage power supplies. In arc
welding, the voltage is directly related to the length of the arc, and the current is
related to the amount of heat input. Constant current power supplies are most
often used for manual welding processes such as gas tungsten arc welding and
shielded metal arc welding, because they maintain a relatively constant current
even as the voltage varies.
 FIG 5.4 WEDING OPERATION

This is important because in manual welding, it can be difficult to hold the

electrode perfectly steady, and as a result, the arc length and thus voltage tend to
fluctuate. Constant voltage power supplies hold the voltage constant and vary the
current, and as a result, are most often used for automated welding processes such
as gas metal arc welding, flux cored arc welding, and submerged arc welding.

In these processes, arc length is kept constant, since any fluctuation in the
distance between the wire and the base material is quickly rectified by a large
change in current.

For example, if the wire and the base material get too close, the current will
rapidly increase, which in turn causes the heat to increase and the tip of the wire
to melt, returning it to its original separation distance.

5.1.3 DRILLNG

Drilling is a cutting process that uses a drill bit to cut a hole of

circular cross-section in solid materials. The drill bit is usually a rotary cutting
tool, often multi-point. The bit is pressed against the work-piece and rotated at
rates from hundreds to thousands of revolutions per minute. This forces the
cutting edge against the work-piece, cutting off chips (swarf) from the hole as it
is drilled.

In rock drilling, the hole is usually not made through a circular cutting
motion, though the bit is usually rotated. Instead, the hole is usually made by
hammering a drill bit into the hole with quickly repeated short movements. The
hammering action can be performed from outside the hole (top-hammer drill) or
within the hole (down-the-hole drill, DTH). Drills used for horizontal drilling are
called drifter drills.

FIG 5.5 RADIAL DRILLING MACHINE

Orbital drilling is based on rotating a cutting tool around its own axis and
simultaneously about a centre axis which is off-set from the axis of the cutting
tool. The cutting tool can then be moved simultaneously in an axial direction to
drill or machine a hole – and/or combined with an arbitrary sidewards motion to
machine an opening or cavity. By adjusting the offset, a cutting tool of a specific
diameter can be used to drill holes of different diameters as illustrated. This
implies that the cutting tool inventory can be substantially reduced.

Drilling may affect the mechanical properties of the workpiece by creating

low residual stresses around the hole opening and a very thin layer of
highly stressed and disturbed material on the newly formed surface. This causes
the workpiece to become more susceptible to corrosion and crack propagation at
the stressed surface. A finish operation may be done to avoid these detrimental
conditions. For fluted drill bits, any chips are removed via the flutes. Chips may
form long spirals or small flakes, depending on the material, and process
parameters

The term orbital drilling comes from that the cutting tool “orbits” around
the hole center. The mechanically forced, dynamic offset in orbital drilling has
several advantages compared to conventional drilling that drastically increases
the hole precision. The lower thrust force results in a burr-less hole when drilling
in metals. When drilling in composite materials the problem with delamination is
eliminated.
5.2 MATERIALS USED

S.NO DESCRIPTION QUANTITY MATERIAL

1 DC MOTOR 1 ELECTRICAL

AS PER
2 SHAFT REQUIREMENTS MILD STEEL

3. BLADE 2 MILD STEEL

STAINLESS
4 BEARING 2 STEEL

AS PER
5 FRAME REQIREMENTS MILD STEEL

5.3COST ESTIMATION

S.NO DESCRIPTION COST

1 DC MOTOR 1600

2 SHAFT 400
3 BLADE 800

4 BEARING 600

5 FRAME 900

5.4 ADVANTAGES & APPLICATIONS

5.4.1 ADVANTAGES

 They can cut through tougher grass with ease.

 There's no cord to limit mobility.
 They have the ability to mow larger areas without waiting for a battery to
charge.
 A little bit of gas goes a long way when mowing a lawn.

5.4.2 APPLICATIONS

 Sickle is the most common kind of grass cutter that most homeowners use.
Mowers may be rotary types, where blades swirl horizontal to the ground,
or reel mowers where blades cut vertically.
 Typically gas or electric powered, rotary mowers may be self-propelled or
rely on manpower to make them move.
 For large areas, reel mowers are pulled behind lawn tractors.
 CHAPTER 6

CONCLUSION AND REFERENCE

CONCLUSION

The crop cutter is designed, fabricated and tested. This machine does not
employees any use of gears and it is fully human operated. The use of this
machine makes the harvesting process faster hence

reduce most of the cutting time and labour required to operate the machine is
also less. This machine is helpful for small as well as big firms. This human
powered machine will help to improve an economical condition. This is new
type of machine which is different to the other cutting machine which are used
for harvesting purpose till now.

REFERENCES

1. . S.M. Pedersen, S. Fountas, H. Have and B.S. Blackmore, “

Agricultural robots: an economic feasibility study”, Department
of Soil Science,Precision Agriculture 2005,pp. 589-596\

2. . Cameron Morland, “Autonomous Lawnmower Control”

3. Kathryn A. Daltorio, Amaury D. Rolin, Jonathan A. Beno, Bradley
E. Hughes, Alexander Schepelmann, Michael S. Branicky, Roger
D. Quinn, “An Obstacle-Edging Reflex for an Autonomous

Lawnmower”, The 2008 and 2009 annual robotic competitions

were sponsored by the Institute of Navigation (ION). 2009,
Western Reserve

4. Design of Machine Elements, V. B. Bhandari ; Mc Graw

Hill Publications; Third Edition

5. PSG Design Data Book

6. Kinematics and kinetic analysis of the slider-crank mechanism in

otto linear four cylinder Z24 engine, March 2011, Journal of
Mechanical Engineering Research

7. Design & Modification of Chaff Cutting Machine, April-

2016 ,International Research Journal of Engineering and
Technology (IRJET)

8. Zakiuddin K.S., Modak J.P. 2010. Design and Development of

the Human Energized Chaff Cutter. New York Science Journal.