ABSTRACT

In this Pedal operated maize shelling machine which is operated by human effort which means
by pedaling which is used for maize shelling operation. In this machine, sprocket and chain
mechanism is used, laid on the sprockets at the pedal end and at the main shaft in the horizontal
direction. A cast iron flywheel was also fitted on this shaft which was used to store rotational
energy, and also a set of another chain and sprocket was fixed on this shaft in the vertical
direction connecting the shaft and bearing of the shelling unit. The shelling unit has a rotating
disc plate. The disc has tapered teeth on its surface, which causes the shelling of seed from the
cob. As in the case of farmers with the small land within less than 2 hector, as they have less
production, with implementation of large machine with labor would be costlier. Keeping this fact
in mind and providing alternative solution for shelling of corn to small scale and poor farmers,
we are designed small manually operated maize shelling machine which operates without
electricity. The machine should be such that it should be adopted by the farmers who produce the
maize in small scale. It is designed to reduce the cost of device, which separates the maize seeds
from its cob which every individual farmer needs in their periodical agricultural activities. Size
of the machine is convenient such that it is easily transported from one place to another place by
help of transporting wheel.

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 ACKNOWLEDGEMENT
First of all, we would like to thanks our almighty God for giving us strength to accomplish this
project work.

Next, we went to express our gratitude for our esteemed instructor Mr. Melak. M for his
guidance and giving an appropriate answer for my question throughout the period of project
work.

Finally, we went to thank our friends for their considerable contribution for successfully
completion of our project work.

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Contents
ABSTRACT.................................................................................................................................................. 1
ACKNOWLEDGEMENT ............................................................................................................................ 2
CHAPTER ONE ........................................................................................................................................... 1
1. INTRODUCTION ................................................................................................................................ 1
1.1. Background ................................................................................................................................... 1
1.2. Problem statement ......................................................................................................................... 2
1.3. Significance of the project ............................................................................................................ 2
1.4. Main objective .............................................................................................................................. 2
1.4.1. Specific objective .................................................................................................................. 2
CHAPTER TWO .......................................................................................................................................... 3
2. REVIEW OF LITERATURE ............................................................................................................... 3
CHAPTER THREE ...................................................................................................................................... 7
3. MATERIALS AND METHODS .............................................................................................................. 7
3.1. Material selection ............................................................................................................................... 7
3.2. Project methodology .......................................................................................................................... 8
CHAPTER FOUR..................................................................................................................................... 9
4. DESIGN PROCEDURE ............................................................................................................................. 9
4.1. Design consideration .......................................................................................................................... 9
4.1.1. Force required for maize shelling ............................................................................................... 9
4.2. Parts design ...................................................................................................................................... 10
4.2.1. Design of chain and sprockets .................................................................................................. 10
4.2.2. Design of flywheel .................................................................................................................... 12
4.2.3.Design of small chain and sprocket ........................................................................................... 15
4.2.4. Design of shaft .......................................................................................................................... 17
4.2.4.1. Design of bearing shaft .......................................................................................................... 19
4.2.5. Selection of bearing .................................................................................................................. 20
4.2.6. Design of key ............................................................................................................................. 20
4.2.7. Design of Sheller ....................................................................................................................... 21

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 4.2.9. Design of adjustable spring ....................................................................................................... 21
CHAPTER FIVE ........................................................................................................................................ 23
5. RESULTS AND DISCUSSION ............................................................................................................. 23
CHAPTER 6 ............................................................................................................................................... 24
6. CONCLUSION ....................................................................................................................................... 24

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5
 CHAPTER ONE

1. INTRODUCTION
Maize shelling a post-harvest operation is the removal of maize seeds from the cob. This
operation can be carried out in the field or at the storage environment. Maize shelling therefore is
an important step towards the processing of maize to its various finished products like flour. The
different methods of maize shelling can be categorized based on various mechanization
technology used. These includes: hand tool technology, animal technology, and engine power
technology. Hand technology involves the use of and tools in shelling, while as observed animals
were used in threshing on the field by marching on the maize, but it has the following limitation
as follows: -

 The operation is highly tedious, inefficient and time consuming with low productivity as
worker can only shell a few kilograms per hour.

Since Engine powered technology involves the use of mechanical assistance in threshing
or shelling the maize. To facilitate speedy shelling of maize in order to reduce post-harvest
deterioration, mechanical sellers are recommended, for overcoming the above mentioned
limitations, however the power operated maize seller machine requires electrical energy for.
Its working and its capital investment is also high compared to the conventional methods of.
shelling but in rural areas supply of electricity is not good at all times. So in order to suit the.
Prevailing condition and reduce the capital investment and operating costs, pedal operated.
maize sheller needs to be developed.

1.1. Background
Maize (Zea mays) is one of the most common cereal grain grown in the world. It belongs to a
grass family (Gramineae) and originated from Mexico and South America. The plant prefers
light (sandy), medium (loamy), and heavy (clay) soils and requires well-drained soil. It cannot
grow in the shade and also requires moist soils. The period between planting and harvesting for
maize t time the kernel contains 35 to 40% moisture and has the maximum content of dry matter.
Maize shelling is difficult at moisture content above 25%, with this moisture content, grain
stripping efficiency is very poor with high operational energy and causing mechanical damage to

1
the seed. A more efficient shelling is achieved when the grain has been suitably dry to 13 to 14%
moisture content.

1.2. Problem statement

In Ethiopia, shelling of maize is done by traditional methods which result into low in efficiency,
time consuming with low productivity as worker can only shell a few kilogram per hour, high
level of wastage and exerting much labor, so in order to overcome those limitations and the cost
of purchasing such electric motor operated Sheller were high for the poor rural farmer, and
therefore necessitated the design of low cost system that will be affordable and also increase
threshing efficiency but reduce damage done to the seed.

1.3. Significance of the project

Maize is shelled traditionally by hands. This is done in such a way that maize is rubbed against
another until the grains are removed from the cob. Likewise, the grain can be detached from the
cob with the use of pestle and mortal. But this traditional method of shelling is highly tedious,
inefficient and time consuming with low productivity as worker can only shell a few kilograms
per hour (FAO, 2005), and also the power operated maize seller machine requires electrical
energy for its working and its capital investment is also high compared to the conventional
methods of shelling as well as in rural areas supply of electricity is not good at all times. So in
order to overcome the limitations that mentioned in the traditional methods and reduce the
capital investment and operating costs, pedal operated maize Sheller needs to be developed.

1.4. Main objective

Design of pedal operated maize shelling machine with increasing productivity and reduce time
where shelling operation is taken in traditional methods.

1.4.1. Specific objective

While in design of pedal operated maize sheller, we'll active the following advantages:

1. Understanding mechanism of shelling operation

2. Understanding techniques of agricultural machinery designing

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 CHAPTER TWO

2. REVIEW OF LITERATURE
Corn shelling is always a typical job as it needs precision and carefully shelling of Corn, so as
the Corn wouldn’t break while shelling. Shelling manually is inefficient process. We are trying
to make a pedal operated machine which can improve productivity aids of profit of shelled Corns
and reduce effort as well as to compromise high investing capital in poor rural farmers. So the
following literatures were studied for designing of our project model.

1. Y.V mahatale and p.VPathak "Physiological Evaluation of Different Manually Operated

Corn Shelling Methods”

Corn is the Third largest cereal produced in the world with a trend of rising production in India.
The normal area for Corn in India was 77.27 lakh hectares with production about 150.91 lakh
tones in the year 2007. Rajasthan has the largest area 10.62 lakh hectares under cultivation
among all states with total production of 21 lakh tones. Four method of Corn shelling namely
shelling cob grain by hand, octagonal Corn Sheller, hand operated Corn Sheller and beating by
stick method were carried for removing Corn kernel from the cob. For ergonomically evaluation
ten male agricultural subjects of 25-35-year age group were randomly selected for study. Present
traditional method of shelling Corn has proved to be inefficient, laborious, time consuming and
low output. The energy expenditure rate was highest for beating by stick method (3.84 kcal/min)
and lowest for octagonal Corn Sheller (1.52 kcal/min). Traditionally Corn is threshed by shelling
cob grain by hand and beating the cob by stick. At present Corn shelling has been improved by
the use of tubular Corn Sheller and hand operated Sheller. The energy expenditure rate was
highest for beating by stick method (3.84 kcal/min) and lowest for octagonal Corn Sheller (1.52

3
kcal/min). Energy expenditure rate for shelling cob grain by hand and octagonal Corn shelling
operation could be scaled in “Very light” category of work load. Whereas the hand operated
Corn Sheller and beating by stick method could be scaled as in “Light” category of work load.
For Corn shelling operations octagonal Corn Sheller and hand operated Corn shelling are
superior than shelling cob grain by hand and beating by stick Method.

2.Ilori T. A., Raji A. O and O. Kilanko “Modeling Some Ergonomic Parameters with Machine
Parameter using Hand Powered Corn Sheller”

In this paper the author studied about the economic situation in most developing countries have
left farmers and processors operating at the small scale, hence the use of automated and electric
power driven equipment is limited to the few large scale industries. The effect of the ergonomic
parameters namely; weight, age, height and arm length in relation to the resulting efficiencies;
shelling efficiency, cleaning efficiency, mechanical damage and percentage loss of a hand
powered Corn Sheller were studied. It
was observed by the author that age is more correlated with weight than arm length. From the
results obtained in this study, the following conclusions were drawn; the shelling efficiency
increase with increases in weight of the operator and significantly with age and arm length. The
weight of the operator has a great influence when driving the machine. The mechanical damage
observed from the performance evaluation has very low correlation with the ergonomic
parameters.

3. B. Ashwin Kumar and ShaikHaneefa Begum “Design, Development and Performance

Evaluation of a Hand Operated Maize Sheller”

The author conducted a research on design, development and evaluation of hand operated Corn
Sheller in College of Agricultural Engineering during the year 2012-2013.The traditional
shelling methods are rubbing the Corn cobs against each another, rubbing on bricks or stone and
by using iron cylinder consisting of wire mesh inside. These methods are time consuming
involves drudgery. In view of this, the study was undertaken to design, development and
evaluation of hand operated Corn Sheller. The Corn Sheller consisted of a cylinder and a
concave. The cylinder made up of high carbon steel of size diameter 21 cm. The cylinder length
86 cm, having beaters which rotates along the cylinder and separates grains from the cobs. While

4
the concave was fabricated using 5 mm size mild steel rods. The length of concave was 91 cm
with slotted opening size of 30.3cm×2.5cm. It was observed by the author that for hand operated
Corn Sheller at a moisture content of 12% w.b. and at a feed rate of 130kg/h, the shelling
efficiency, unshelled percentage and visible damage was found to be 99.56%, 0.44% and 1.07%,
respectively.

4. Oriaku E.C, Iguana C.N, Nwannewuihe H.U, Onwukwe M.C and Adiele, I.D “Design and
Performance Evaluation of a Corn De-Cobbing and Separating Machine”

Here the author told that, Agricultural products like maize, soya bean, millet and rice, when
processed into quality forms not only prolongs the useful life of these products, but increases the
net profit farmers make from mechanization technologies of such products. One of the most
important processing operations done to bring out the quality of maize is de-cobbling or
threshing of maize. Consequently, a de-cobbling and separation machine was designed,
fabricated and its performance evaluated. Corn at moisture content of 15.14% db sourced locally
was used in the experiment and the data collected were analyzed. Results showed that for a total
20kg of sample tested, the average feed and threshing time were 2.37 and 2.95 minutes
respectively. The average feed and threshing rates were 2.06 and 1.65 kg/min with an average
threshing efficiency of 78.93 %. The average separation efficiency was 56.06 %. These results
indicate that threshing and separation can be performed out satisfactorily with the designed
machine and it can be used to process about 1 tons of maize per nine-hour shift.

5. Kajogbola et al. (2010) designed and developed a pedal soap mixer.

The machine consists of a chain drive and gear amplification mechanisms that turns impeller
blades in a large stainless steel container, where soap ingredients are stirred and blended. The
machine is economically viable, can be used by unskilled workers, save time otherwise spent in
traditional mixing and can be adopted for human-powered operational units which could have
intermittent operation without affecting the end-product.

6.Bahaley et al. (2012) analyzed the performance of pedal powered multipurpose Machine. A
human powered multipurpose machine was developed which lifts water to a height 10 meter and
generates 14 Volt, 4 ampere of electricity in most effective way. Power required for pedaling
was well below the capacity of an average healthy human being. The system was also found

5
useful for the work out purpose because pedaling will act as a health exercise and also doing a
useful work.

7. Tambari (2015) designed and fabricated of a pedal powered hacksaw cutting machine.
The aim of this work is to develop a modernized and less stressful operation for cutting wood,
metals and plastic materials. It is very useful for cutting PVC materials (pipes) and can be used
widely in lather and in furniture making industries. This work can also serve as an exercising
machine for fitness while cutting; it uses the principle of a slider crank mechanism which
converts the rotary motion of the flywheel to the reciprocating motion of the hacksaw during
pedaling. The machine was tested and continued to be very efficient with an ideal mechanical
Advantage of 0.5 (less than 1), velocity ratio of 0.65 (less than 1), a power output of 5.72 KW
and an efficiency of 76.9%, which makes it very adequate and capable for cutting.

8. Tiwari et al. (2010) explained operating speed of rotary maize sheller was optimized for its
operation at higher operating speeds in pedaling mode, by conducting a simulation study for
three sizes of maize cobs at seven operating speeds. The shelling capacity and shelling efficiency
of maize sheller for all categories of maize cobs increased curvilinear with increased in operating
speed up to about 70 r.p.m. The shelling capacity at a particular operating speed decreased with
increased in the maximum diameter of cobs. Operating torque of rotary maize Sheller for a given
size of maize cobs decreased with increased in operating speed. On the other hand, the torque
decreased with decreased in maximum diameter of maize cobs at a given operating speed. It was
concluded that the operating speed of maize Sheller should be 70 to 80 r.p.m for higher shelling
capacity, shelling efficiency and lower operating torque.

Advantages

The advantage of designed and fabricated of a pedal powered hacksaw cutting machine that conducted
by Tamari (2015) are as follows: -

1. Resisted changes in rotational speed and provided continuous energy when the energy source
was discontinuous by help of flywheel. The flywheel also serves as energy reservoirs that stores
energy when it is excess and release it when there is shortage of energy within the system.

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2. It has an ideal mechanical Advantage of 0.5 (less than 1), velocity ratio of 0.65 (less than 1), a
power output of 5.72 KW and an efficiency of 76.9%, which makes it very adequate and capable
for cutting.

Disadvantages

1. The machine may require high man pedaling power, so that it requires more than one labor for
performing its intended function.

2. It is preparing for cutting purpose only, which is not agricultural.

Since, our design project focus on pedal operated maize Sheller by considering the above
mentioned advantages.

CHAPTER THREE

3. MATERIALS AND METHODS

3.1. Material selection

Selection of proper materials for manufacturing various components of maize sheller is very
important. The farm machinery has to work under several hazardous and heterogeneous
environmental conditions. It should be adequately strong, stiff, and wear, corrosion resistant and
serves the purpose and operating requirements of the maize Sheller parts. It should be readily
shaped, welded and machined. The materials for construction of different components should be
easily and locally available. Use of standard sizes of bearing with house, fasteners and chains
would help in easy inter -changeability and replacement. The structure of power transmission
unit should be simple, that is why, the operation, maintenance and repair easy. So Before starting
the construction of maize shelling machine, the following factors are considered for appropriate
selection of materials. Selection of metal must be such that it can be formed into desired shape.it
depends on the ductility characteristics of metals. The materials for construction of various
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components must selected as considering their function and strength requirements as well as the
economic consideration and ease availability of materials also taken into account. Therefore,
according to the above mentioned requirement such the material use for pedal operated maize
sheller are listed in the table below.

Table.3.1. Materials used for fabrication of pedal operated maize Sheller

No Parts material used

1 Frame Mild steel

2 Shelling disc plate with provide zig zag teeth Mild steel
(spikes).

3 Chain and sprocket Stainless steel sprocket and cast iron chin

4 Shaft Mild steel

5 Flywheel Cast iron

6 Bearing house Cast iron

7 Pedal Rubber and Stainless steel

8 Transporting wheel PVC

9 Adjustable spring Hardened steel

3.2. Project methodology

Before we started the process of project work, it is necessary to have adequate knowledge about
project design essential to design the project and also before starting manufacturing.

So, we have to follow the following procedures through our project work.

Make a detailed statement of the problems completely; it should be as clear as possible and also
of the purpose for which the machine is to be designed.

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Evaluate the significance of the project.

We have to studied some literatures work, and taken some advantages among them.

Select the suitable material for each parts of the machine.

Design each elements of the machine.

Evaluate the result of the work and to be conclude it with respect of given result.

Make assembly and detail drawings of machine with complete specification for the materials and
manufacturing method i.e. accuracy, surface finish etc

CHAPTER FOUR

4. DESIGN PROCEDURE

4.1. Design consideration

While, designing of maize Sheller should be conceder the following points are listed below: -

 Maximum force required to shelled the corn

 Shelling speed (velocity ratio)
 Standard size of corn
 Material of machine components
Since similar works dealing with pedal machine were done by kajogbola et al, (2010) and
tambari(2015).so their machine to be developed was aimed for single person. Thus, the total
weight of the machine was 52.5kg. Those considerations that maintained above were taken into
account.

4.1.1. Force required for maize shelling

The force required to single kernel from maize cob ranges =3.89 – 17.33N (Sharma, 2007).
Number grain in a single cob varies =400 – 600, so force required for one whole maize varies =
1556 -10398N.

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4.2. Parts design

4.2.1. Design of chain and sprockets

The chain is mostly used to transmit motion and power from one shaft to another. The distance
between the centers of shafts was short. The main advantage of thin chain drive is giving high
transmission efficiency as no slippage takes place.

4.2.1.1. Calculations
In our design case one set of chain and sprocket is used at the pedal side and another is used to
connect at the main shaft in the horizontal direction. Since according to Tambar (2015) we know
the value of ideal mechanical advantage of IMA=0.5.

𝜔 𝑁
Let, IMA=𝜔 𝑖𝑛 = 𝑁 𝑖𝑛
𝑜𝑢𝑡 𝑜𝑢𝑡

Where: -

𝑁𝑖𝑛 =𝑁2 = rotational speed of larger sprocket in rpm

𝑁𝑜𝑢𝑡 =𝑁1 = rotational speed of smaller sprocket in rpm

So, using 𝑁𝑖𝑛 = 80rpm (Tiwari et al,2010) for higher shelling capacity
80𝑟𝑝𝑚 80𝑟𝑝𝑚
Thus, 0.5 = → 𝑁𝑜𝑢𝑡 = = 160rpm
𝑁𝑜𝑢𝑡 0.5

Now we can determine the velocity ratio of the chain drive as follow: -

𝑁 𝑇
VR = 𝑁1 = 𝑇2
2 1

Where: -

𝑇1 = number of teeth on the smaller sprocket

𝑇2 = number of sprocket on the larger sprocket

160𝑟𝑝𝑚
Thus, VR = =2
80𝑟𝑝𝑚

From table 21.5, we find that for the roller chain, the number of teeth on the smaller sprocket or
pinion (𝑇1 ) for the velocity ratio of VR=2 is 27

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 𝑇
Thus, 2 = 272 → 𝑇2 = 2× 27 = 54

We know that the design power of 𝑃𝑑 = rated power × service factor

Now, assumed that 𝑃𝑟𝑎𝑡𝑒𝑑 = 𝑃𝑜𝑢𝑡

So, according to tamber (2010), ɳ𝑠𝑦𝑠𝑡𝑒𝑚 =76.9% and 𝑃𝑜𝑢𝑡 =5.72KW

𝑃𝑜𝑢𝑡 𝑃𝑜𝑢𝑡 5.72𝐾𝑊

Thus, ɳ𝑠𝑦𝑠𝑡𝑒𝑚 = → 𝑃𝑖𝑛 = ɳ = =7.44KW
𝑃𝑖𝑛 𝑠𝑦𝑠𝑡𝑒𝑚 0.769

The service factor (𝐾𝑠 ) is the product of various factor 𝐾1 , 𝐾2 𝑎𝑛𝑑𝐾3 . The value of the factors is
taken as follows

Load factor (𝐾1 ) for constant load = 1

Lubrication factor (𝐾2 ) for periodic lubrication = 1.5

Rating factor (𝐾3 ) for 8 hour per day = 1

Therefore, 𝐾𝑠 = 𝐾1 × 𝐾2 × 𝐾3 = 1× 1.5 × 1 = 1.5

And, 𝑃𝑑 = 5.72KW × 1.5 = 8.58𝐾𝑊

From table 21.1(kurmi), we find the value of pitch of chain,

P=9.525mm

And maximum width of roller, w =6.35mm

We know that pitch circle diameter of the smaller sprocket or pinion is given as follow,

𝑝 9.525𝑚𝑚
𝑑1 = 180 = 180 = 82.04mm say 82mm
𝑠𝑖𝑛 𝑠𝑖𝑛
𝑇1 27

And pitch circle diameter of the larger sprocket is given by

𝑝 9.525
𝑑2 = = 180 = 180 = 163.815mm say 164mm
𝑠𝑖𝑛 𝑠𝑖𝑛
𝑇2 54

Pitch line velocity of the smaller sprocket is

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 𝜋×𝑑1 ×𝑁1 3.14×0.082𝑚×160𝑟𝑝𝑚
V= = = 0.7 m/s
60 60

Therefore, load on the chain is

𝑁𝑚
𝑃𝑟𝑎𝑡𝑒𝑑 5.72×103 𝑠
W= = ( 𝑚 )= 8.17KN
𝑉 0.7
𝑠

𝑊𝐵
And factor of safety (n) = , take𝑊𝐵 = 20KN
𝑊

20𝐾𝑁
Thus, n = 8.17𝐾𝑁 = 2.4479 say 3

The center distance between sprockets is given as follow

X = 30P = 30 × 9.525mm = 285.75mm

The exact length of the chain (L) is determined as

𝑇1 +𝑇2 𝑝/2 𝑝/2

L = {p( ) +2x +[ 180 − 180 ] ÷x}…………………………(*)
2 𝑠𝑖𝑛 𝑠𝑖𝑛
𝑇1 𝑇2

Pedal side chain length from equation (*)

27+54 9.525/2 9.525/2

L = {9.525mm × ( ) + 2× 285.75mm + [ 180 − 180 ] ÷ 285.75𝑚𝑚}
2 𝑠𝑖𝑛 𝑠𝑖𝑛
27 54

L = 957.119mm ≅ 960mm

Since, we know that the input power value and the angular velocity of the larger sprocket, so we
can determine the input torque as follow,

2𝜋×𝑁𝑖𝑛 60𝑃 60×7.44𝐾𝑊

𝑃𝑖𝑛 = 𝑇𝑖𝑛 × 𝜔𝑖𝑛 =𝑇𝑖𝑛 × → 𝑇𝑖𝑛 = 2𝜋×𝑁 = = 888.54N-m
60 𝑖𝑛 2𝜋×80𝑟𝑝𝑚

𝑇𝑖𝑛 888.54𝑁−𝑚
And, 𝐹𝑖𝑛 = 𝐹𝑑𝑠𝑖𝑔𝑛 = 𝑑2 = 0.178𝑚 = 9983.6N
2 2

Therefore, the design force value was found along the range of the force required for one whole
maize varies = 1556 – 10398N, so the design is safe.

4.2.2. Design of flywheel

A flywheel used in machines serves as a reservoir which stores energy during the period when
the supply of energy is more than the requirement and releases it during the period when the

12
requirement of energy is more than supply. In our design case it is mounted on the horizontal
rotating shift where it is to regulate the fluctuation speed during pedaling of the system.

4.2.2.1. Design Approach

There are two stages to the design of a flywheel.

1. The amount of energy required for the desired degree of smoothening must be found and the
(mass) moment of inertia needed to absorb that energy determined.

2. The flywheel geometry must be defined that Gets the required moment of inertia in a
reasonably sized package and is safe against failure at the designed speeds of operation.

4.2.2.2 Calculation
The change in the shaft speed during a cycle is called the speed fluctuation and equal to

2𝜋𝑁𝑚𝑎𝑥 2𝜋𝑁𝑚𝑖𝑛
𝐹𝑠 = 𝜔𝑚𝑎𝑥 − 𝜔𝑚𝑖𝑛 = −
60 60

Where: -

𝜔𝑚𝑎𝑥 =𝜔1= angular velocity of smaller sprocket

𝜔𝑚𝑖𝑛 = 𝜔2 = angular velocity of larger sprocket

𝑁𝑚𝑎𝑥 = 𝑁1 = speed of smaller sprocket = 80rpm

𝑁𝑚𝑖𝑛= 𝑁𝑚𝑖𝑛 = speed of larger sprocket = 160 rpm

2𝜋160 2𝜋80
Thus, 𝐹𝑠 = - = 8.3775 rad/s
60 60

And according to the class of service we can obtained the permissible value of co-efficient speed
from the table 22.1 (kurmi). So for power with belt (chain) transmission of fluctuation, the value
of co-efficient speed of 𝐶𝑓 = 0.030

When a flywheel absorbs energy its speed increased and when it gives up energy its speed
decreased.

Now we can assume the diameter and mass of flywheel of 0.35m and 20kg respectively.

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And the value of mass moment of inertia can be determined as follow,

I = m× 𝑘 2…………………………………………………………………(∗∗)

Where: -

K = the radiation of gyration may be equal to the mean radius off the fly wheel (rim) of R,
because the thickness of rim is very small as compare to the diameter of rim. Therefore, we can
be substituting k=R in equation (**), we have

I = 20kg × 0.1752 = 0.6125 kg-𝑚2

We know that the change in kinetic energy of flywheel is

∆𝐸= maximum kinetic energy – minimum kinetic energy

2𝜋×160 2
∆𝐸 = ½ × I × 𝜔12 × 𝐶𝑠 – ½ × I × 𝜔22 × 𝐶𝑠 = ½ × 0.6125 × ( ) 0.030 – ½ × 0.6125 ×
60
2𝜋×80 2
( ) ×0.03
60

= 2.57925 – 0.6448 = 1.93 N-m

And we determine the volume of the flywheel as follow,

𝑚
V= 𝜌

Where: -

V= volume of fly wheel in 𝑚3

m= mass of flywheel in kg

𝜌 = density of cast iron flywheel is 7260kg/𝑚3

Therefore,

20𝑘𝑔
V = 7260𝑘𝑔/𝑚3 = 2.755× 10−3 𝑚3

And, load on the shaft can be calculate as follow: -

14
 W = m×g

Where: -

g= gravitational acceleration = 9.81m/𝑠 2

Thus, W = 20𝑘𝑔 ×9.81m/𝑠 2 = 196.2N

4.2.3. Design of small chain and sprocket

The chain is used to transmit power and motion from main shaft to bearing shaft of shelling unit.

We know that the value of machine velocity ratio according to tamber (2010).

𝑵 𝑵
So, V.R = 𝑵𝟏 = 0.65 → 𝑵𝟐 = 𝑽.𝑹𝟏
𝟐

Where: -

𝑵𝟏 = input speed of the machine is 80rpm

𝑵𝟐 = main shaft speed

Thus, 𝑵𝟐 = 80𝒓𝒑𝒎 × 0.65 = 123.08rpm

And, 𝑻𝟏 𝑵𝟏 =𝑻𝟐 𝑵𝟐

Where: -

𝑻𝟏 = input torque of machine = 888.54N-m

𝑻𝟐 = main shaft torque

𝑻𝟏 ×𝑵𝟏 𝟖𝟖𝟖.𝟓𝟒𝟒𝑵−𝒎×𝟖𝟎𝒓𝒑𝒎
Therefore, 𝑻𝟐 = = = 577.54N-m
𝑵𝟐 𝟏𝟐𝟑.𝟎𝟖𝒓𝒑𝒎

Now, take the velocity ratio of small chain of V.R = 1.5, and from table 21.5, we find that for the
roller chain, the number of teeth on the smaller sprocket or pinion (𝑇1 ) for the velocity ratio of
VR=1.5 is 29

15
Therefore, number of teeth larger sprocket can be calculating as follow,

𝑇
𝑉. 𝑅 = 𝑇2 =1.5 → 𝑇2 = 𝑇1 × 𝑉. 𝑅
1

𝑇2 = 29×1.5= 43.5≅ 44

And take the following parameters value from the table 21.1 (kurmi).

P=pitch of chain = 9.5mm

𝑑1 =maximum roller diameter = 6.35mm

𝑏1 = maximum width between inner plate = 5.72mm

The center distance between sprockets is given by

X = 30p = 30×9.5mm= 285mm

And, the exact length of the chain (L) is determine as

𝑝 𝑝
𝑇1 +𝑇2 2 2
L = {p ( ) + 2X + [ 180 − 1800 ] ÷ 𝑋}
2 sin( ) sin( )
𝑇1 𝑇2

9.5𝑚𝑚 9.5𝑚𝑚
29+44 2 2
L = {9.5mm ( ) + 2×285mm + [ 180 − 180 ] ÷ 285𝑚𝑚}
2 𝑠𝑖𝑛 𝑠𝑖𝑛
29 44

L = 916.75mm -0.07948mm = 916.67mm

And, we know that pitch circle diameter of the smaller sprocket or pinion is given as follow,

𝑝 9.5𝑚𝑚
𝑑1 = 180 = 180 = 87.8mm say 88mm
𝑠𝑖𝑛 𝑠𝑖𝑛
𝑇1 29

And pitch circle diameter of the larger sprocket is given by

𝑝 9.5𝑚𝑚
𝑑2 = = 180 = 180 = 133.16mm
𝑠𝑖𝑛 𝑠𝑖𝑛
𝑇2 44

Pitch line velocity of the smaller sprocket is

𝜋×𝑑1 ×𝑁2 3.14×0.088𝑚×123.08𝑟𝑝𝑚

V= = = 0.6m/s
60 60

16
Therefore, load on the chain is

𝑃𝑟𝑎𝑡𝑒𝑑
W= 𝑉

5.72𝐾𝑁𝑚/𝑠
Thus, W= = 9.5KN
0.6𝑚/𝑠

4.2.4. Design of shaft

A shaft is a rotating machine element which is used to transmit power from one place to
another. In our design case it is made up of mild steel and it is expected to be subjected to both
tensional and bending moment. So according to maximum shear stress theory, the diameter of
shaft can be estimate as follow,

𝟏𝟔
𝒅𝟑 = (𝝅𝝉 )× 𝑻𝒆
𝒎𝒂𝒙

Where: -

𝑻𝒆 = the equivalent twisting moment

= √𝑴𝟐 + 𝑻𝟐

𝝉𝒎𝒂𝒙 = maximum shear stress of the material is take 42Mpa for shafts with allowance of keyways

M= maximum bending stress of the shaft

T= maximum twisting moment of the given shaft

While, the input torque transfer to the rotating horizontal shaft with the help of chain drive the
shaft twisting moment can be determined as follow: -

𝑻𝟏 𝑵𝟏
𝑻𝟏 𝑵𝟏 = 𝑻𝟐 𝑵𝟐 → 𝑻𝟐 = 𝑵𝟐

Where: -

𝑻𝟏 = the input twisting moment = 888.54N-m

𝑻𝟐 = the shaft twisting moment

17
𝑵𝟏 = speed of larger sprocket = 80rpm

𝑵𝟐 = speed of smaller sprocket =160rpm

𝟖𝟖𝟖.𝟓𝟒𝑵−𝒎×𝟖𝟎𝒓𝒑𝒎
So, 𝑻𝟐 = = 444.27N-m
𝟏𝟔𝟎𝒓𝒑𝒎

Therefore, the maximum twisting movement is the input torque of 𝑻𝟏 = 𝑻 =888.54N-m.

And, the maximum bending moment of the main shaft can be calculating as follow,

9.5KN A B C196.2N

20cm 8.17KN 10cm

∑ 𝑴𝑨 =0

-196.2𝑵 ×0.3m – 8170𝑵 ×0.2m=𝑴𝑨

𝑴𝒃 =-1692N-m

∑ 𝑴𝑩 =0

-9500N× 𝟎. 𝟐𝒎 −196.2𝑵 ×0.1m=𝑴𝑩

𝑴𝒃 =-1919.62N-m

∑ 𝑴𝑪 =0

-9500𝑵 ×0.3m+8170N×0.1m=𝑴𝑪

𝑴𝒃 =-2033N-m

Where, the negative sign which indicate that the direction of moment

Maximum bending moment is 𝑴𝒃 = -2033N-m

Therefore, 𝑻𝒆 =√(−𝟐𝟎𝟑𝟑𝟐 ) + (𝟖𝟖𝟖. 𝟓𝟒𝟐 ) = 2218.6N-m

18
 𝟏𝟔×𝟐𝟐𝟏𝟖.𝟔
And, 𝒅𝟑 = 𝝅×𝟒𝟐×𝟏𝟎𝟔 = 2.6029𝟏𝟎−𝟓 m

𝟑
d= √𝟐. 𝟔𝟎𝟐𝟗𝟏𝟎−𝟓 𝒎 = 0.029635m say 30mm

vertical shear force and bending moment distribution

9.5kN 196.2N

0.2m8.17kN 0.1m

9.5kN 8.17kN

192.6N

4.2.4.1. Design of bearing shaft

This shaft is very short which is used to transmit rotational power from the vertical chain to
rotating disc plate, which subjected to twisting moment only.

Let, d = diameter of bearing shaft

𝟏𝟔×𝑻
And, 𝒅𝟑 =𝝅×𝝉
𝒎𝒂𝒙

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Where: -

T = twisting moment of vertical chain with bearing shaft = 577.54N-m

𝝉𝒎𝒂𝒙 = maximum shear stress of the material without keyway allowance = 56Mpa

𝟑 𝟏𝟔×𝟓𝟕𝟕.𝟓𝟒𝑵−𝒎
So, d =√𝟑.𝟏𝟒×𝟓𝟔×𝟏𝟎𝟔 𝑵/𝒎𝟐 = 0.024178m

d = 24.178mm ≅ 25mm

4.2.5. Selection of bearing

Depending upon the nature of contact we have to choose the antifriction bearing, and we know
what the value of diameter of shaft, which must be closely equal to the bore diameter of Bering,
so in order to that we can read useful criteria from the table 27.1(kurmi) as follow,

Number of bearing = 205

Outside diameter of bearing = 52mm

Width of bearing = 15mm

4.2.6. Design of key

A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley to connect
these together in order to prevent relative motion between them. It is always inserted parallel to
the axis of the shaft. For our project work rectangular sunk key is selected because of its
resistance of torque.

4.2.6.1. Proportion of key

The usual proportion of key are given as follow

W = D / 4 AND T = 2W / 3 = D / 6

Where

d= diameter of shaft = 30mm

20
w= width of key in mm

t= thickness of key in mm

Thus, w = 30mm/4 = 7.8mm say 8mm

And, t = 30mm/6 = 5mm

The length of the key can be calculated as

L = πd/2 = 1.571d

L = 1.57 1×30mm = 47.13mm

4.2.7. Design of Sheller

It is the main part of the shelling unit which is used to remove maize seed from the cob. In order
to estimate the donation of it, we should be considered the size and shape of maize as well as the
overall size of the machine, therefore the estimated dimension is listed in the table below.

Table 4.2.8. Dimensions of Sheller

No Name of compound Dimensions(mm)

1 Disc plate 100mm diameter and 10mm thickness

2 Shelling teeth 12.5mm pitch and 10mm height

4.2.9. Design of adjustable spring

A spring is defined as an elastic body, whose function is to distort when loaded and to recover its
original shape when the load is removed. In our design case we have been chosen compression
helical spring which is made up of stainless steel. It is an adjustable spring which is join on the
shelling unit used to adjust the diameter of the shelling unit according to the size and shape of the
maize.

According to the material property we can obtain the value of allowable shear stress for light
service from the table 23.1. (Kurmi).

21
So, 𝝉𝒂𝒍𝒍 =437.5 mpa

Now, we must have made an assumption for calculate the useful design parameters.

Take, d=40mm, d=4mm.

Where,

D=mean diameter of spring

D=diameter of spring

We know that the spring index

C= d/d= 40mm/10mm = 10

And we can calculate the shear stress factor as follow

𝒌𝒔 = 1 + 1/2c = 1 + 1/2*10 = 1.05

Therefore, the axial load on the spring is given by

𝝅×𝒅𝟑 ×𝝉𝒂𝒍𝒍
W= 𝟖×𝑫×𝒌𝒔

𝟑.𝟏𝟒×𝟒𝟑 ×𝟒𝟑𝟕.𝟓
W= = 261.66N
𝟖×𝟒𝟎×𝟏.𝟎𝟓

W = 261.66N

22
 CHAPTER FIVE

5. RESULTS AND DISCUSSION

Design of pedal maize shelling machine is completed. This project can be applicable for the
farmers who produce maize in small scale. It consists of chain and sprocket, rotating horizontal
shaft, flywheel, bearing shaft, disc plate which has a tapered tooth on its surface, which causes
the shelling of seed from the cob. The rotating disc has a diameter, thickness and teeth height of
10cm, 1.5cm and 1cm respectively. and also the cast iron flywheel used to store rotational energy
and release it when the supply energy is less than the requirement. According to the productivity
it can be reduce high rate of wastage which causing by performing traditional method and no
need more than one labor. since its cost is relatively reasonable for poor farmers.

COST ESTIMATION

Table 5. Cost estimation

No Name of components Cost(ebr)

1 Pedal and sprocket 500

2 Flywheel 300

3 Shaft 150

4 Small chin and sprocket 350

5 Shelling unit 1000

6 Frame 500

7 Transporting wheel 300

8 Miscellaneous 500

Total 3500

23
 CHAPTER 6

6. CONCLUSION

Thus the pedal powered maize shelling machine is designed successfully.

The pedal operated maize shelling machine has the following benefit:

 It is more convenient and easier.

 It is affordable for poor farmers
 Specific power is not required
 Reduce human efforts

While, a low cost and simple design pedal operated maize shelling machine is fabricated, which
can reduce machine the human effort and hence we don’t need two persons to shell the maize.

Pedal power maize speller we can be used in distant places where electricity is not accessible. It
is designed as a transportable one which can be used for shelling in various places. It is also
effective for the human health. Pedal driven speller helps to obtain less effort uniform shelling.

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