DESIGN OF CRITICAL COMPONENT OF CORN CHAFF PEELING MACHINE

International Journal of Mechanical and Production Engineering Research and Development (IJMPERD) ISSN (P): 2249–6890; ISSN (E): 2249–8001 Vol. 10, Issue 3, Jun 2020, 159–172 © TJPRC Pvt. Ltd.

DESIGN OF CRITICAL COMPONENT OF CORN CHAFF PEELING MACHINE MAYUR S. GORAD1 & VINAYAK R. NAIK2 1

Student, Department of Mechanical Engineering, D. K. T. E. Institute, Ichalkaranji, Maharashtra, India 2

Head of Department, Mechanical Engineering, D. K. T. E. Institute, Ichalkaranji, Maharashtra, India

ABSTRACT India is dependent on agriculture for its economic development. Corn plays an important role in the agricultural production. In India, Corn is produced by poor farmers. The price of maize is very cheap as compared to the price of kernel. Lack of Corn utilizing products is a major problem in food industry, especially in India, which is the major producer of corn. Therefore, it is very important to undertake some work for development of various agricultural products related to corn, like Corn seeder, Corn peeler etc. In this work, the detailed information about critical components of Corn peeling machine is presented. In this work, it is necessary to design various parts of Corn chaff peeling machine.

In India, Corn consumption is 787 million bushels which is very high. So, machine or technology is required to combat heavy time consumption and labor problems. In this work, design and analysis of the motorized corn peeling

KEYWORDS: Corn & Peeling Machine

Received: Nov 02, 2019; Accepted: Nov 22, 2019; Published: Apr 28, 2020; Paper Id.: IJMPERDJUN202015

1. INTRODUCTION

Original Article

machine is dealt with proper planning.

1.1 Corn / Maize and its Market in India In India, corn is the most important crop after rice and wheat. The production of Corn is approximately 22.23 MTones during particular season. Indian produces 9 % corn of the world. The distribution of corn production in various countries is shown in figure 1.

Figure 1: Distribution of global corm production during 2018/2019 In India, Corn is produced in all states. Corn is mostly used as grain, fodder, green cobs, sweet corn, baby corn, pop corn. [5]

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Sweet corn is one type of corn, that looks yellow or white or bi-colored. After planting, it is required to have frostfree period to grow. It should be planted in blocks.

Figure 2: Parts of Corn.

There are three main parts of Corn, 

Chaff (Leaf)



Kernels (Seeds)

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Cob (Ear) Maximum size of kernels is 2.5 cm.

Cob holds 600 kernels.

Weight of corn with chaff is 180 grams

2. LITERATURE SURVEY Oriaku E C [1]: In this literature, author has given information related to Corn crop and their production. Corn is the most important crop like other crops in the world. It provides various nutrients to humans and animals. In Africa, Corn plays an important role in recovering from hunger. It is a staple food for poor family. Harvesting, drying, peeling, shelling, storing, and milling are various stages involved during corn production and corn utilization. Technology used in agriculture is always yields profitable benefits for farmers in India.

Anant J. Ghadi and Arunkumar [2]: In this paper, author elaborates various existing Corn threshing methods.

All these existing methods are manual and they are not much effective and economical. Corn production in India plays an important role in economic development. The usage of advanced technology can lead to success. So, it is required to develop different technologies, which should be feasible, economical, secured, and dynamic.

Abdulkadir Baba Hassan [3]: According to this paper, high investment is not required where Corn is produced with many farmers It is not affordable as cost of Corn threshing machines is very high. However, manual threshing method proves to be less effective as it comes with lot of wastage and human effort. So, it is required to adopt machines to process Corn.

Adewole, C. A., Babajide [4]: has explained about maize production and mentions that it has been in occurrence for many years in the world. In addition, there has been many processes followed for Corn production for many years. This paper describes the condition of Corn processing in Nigeria. In Nigeria, Corn shelling, peeling, milling is the time consuming operation and it causes people lot of injuries and pain. Food industry is one of the most important parts of the Impact Factor (JCC): 8.8746

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agricultural field, which is the backbone of the economy in this country. In order to develop the economic condition further, Nigeria needs to concentrate on the development of various technologies of corn processing.

Anirudha G. Darudkar [5]: Corn is cultivated by all types of farmers i.e. small scale, or large-scale farmers in India. Cob or chaff is on upper portion of the corn. Farmers sell that portion. But, this transaction is not profitable for small scale farmers, as the market price for Corn along with Cob is very less compared to the price of Corn seeds. An investigation is required to develop various machineries to remove Chaff, Kernels from Corn. If farmers use machineries, they can remove chaff and kernels from corn and can directly sell to the market with high market price of kernels.

Whereas, previous techniques used to remove Chaff and Kernels were manual and unsecured. In order to overcome the above drawbacks, it is important, to develop more secured, automatic, highly effective and economic product,.

Dr. C. C. Handa [6]: Corn is the most important and widely consumed crop in all countries in the world. There are not many techniques available to processing the Corn. Across the world, Corn production and consumption is very high, however, the processing techniques are poor. In the past, Corn was processed in a manual, and unsecured manner which proved to be time consuming and less effective. Because of which, small scale farmers couldn’t gain enough much profit from Corn production. As farmers were unable to perform initial process, they couldn’t get sufficient price for Corn.

Hence, development of low cost Corn processing machines is necessary for the food industry in the world.

Kedar Patil [7]: Corn in India is one of the most popular crops utilized through human food, animal feed, and through various other ways. Corn is the most important and profitable cultivation in the world. Each and every part of Corn is useful. In India, corn is sold in market once after corn is grown. But, unfortunately farmers do not get reasonable price.

For deseeding and chaff peeling, low cost machines are adopted and due to which, it is possible to overcome the above problem in this economy.

2.1 Summary 

In the past, Corn chaff was removed from the Cob manually by using tools like iron stick.

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The average price of Corn is half of the average price of Kernel.

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Mass shelling can be performed by several electrical operated Corn shelling machines. Unshelled corns were taken to such companies where farmers get their result. i.e. Corn cob without Chaff, which will be sold in the market.

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This project focuses on developing a perfect machine as there is no perfect machine, which peels the leaf from Corn cob.

3. OBJECTIVES 

To improve and optimize the present procedure by doing analysis of screw guide ways.

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To improve simplicity by selecting the proper shape and size of guide ways.

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Minimize the existing blockage of Corn due to improper pitch and threads of screwed guide shaft.

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Develop standard dimensions for guide ways in which each time tailor-made manufacturing method will get

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eliminated, so that unskilled operator can manufacture the guide ways by using proper jig templates. 

To perform analysis of various critical components of the machines like shaft and other rotary members.



To minimize the customers problem during handling of the corn peeler machine. The main problem they are facing is related to guiding of Corn on screwed guide shaft.

4. DESIGN CONSIDERATIONS 4.1 Design Considerations 

Appropriate Machine for corresponding developing abilities.



Use cheap materials and easy developing process.



It should be low cost machine and low-income groups should be able to afford it.



It has been cost effective to develop, work, preserve and reparation.

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Use locally obtainable resources and expertise.

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Durability is a prime consideration so that unwarranted weight should be escaped.

The total Corn and hollow rollers load is 2500 gms = 250N. The screwed shaft outer radius is 10cm We know Power, P =

Where, T = Torque acting on output shaft N-mm N= Speed of guide shaft in rpm P = Motor Power required to drive the shaft in watt Torque on shaft, T = 250 x 50 = 12500 N-mm Speed necessary in between 120 to 280 rpm.

Considering average speed so, N = 175 rpm P = 2x 3.14 x175 x 12500 / (60x1000) P = 228 watt So we have selected 1.0 hp motor.

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Motor speed = 1500 rpm Single phase Motor supply 220 V.

Figure 3: Views of Driving Motor.

4.2 Drive Shaft Design Selection of material is one of the important stages in design process. The main target is to reduce cost by meeting product performance goals. The best material should be selected by their properties and cost. Mostly, improper selection of materials should be responsible for failure of machine. [8] During design, we have to consider C40 for the material to be used for shaft. The material to be selected for shaft is C40, as it is considered as a popular grade.

These roller shafts are manufactured by steel with carbon content ranging from 0.20% to 0.45%, i.e. 30C8 or 40C8.

These are usually named as machinery steels. For shaft design, 40C8 is used [10].

Sut = 630N/mm2, Syt = 350N/mm2, T = Max Torque generated to rotating drive shaft.

Drive Shaft Loading Condition.

As per reference code, The permissible shear stress = 30 percent of yield strength.

The permissible shear stress = 18 percent of the ultimate tensile strength

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After keyways present, the further values reduced by 25%.

Max torsion moment equation is given by,

(a) Where T = 12500 N-mm From equation a Screwed shaft dia d1 = 9.34 mm ……………….A 4.3 Tension in Belt Drive T1 = Tension in one side (tight) T2 = Tension in another side (slake) We know P = v (T1 – T2)

V = 9.42 m/ sec 0.5 x 735 = 9.42 (T1 – T2)

(1)

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T2 = 55N T1 = 94 N Total load on pulley = 55 + 94 = 149 say 150N……………….a 4.4 Maximum Bending Moment Acting on the Input Shaft

From eq (a) the tension due to belt T = T1+T2 = 150N

Taking moment about moment A,

Maximum bending moment,

Ϭ = 158 N/ mm2 factor of safety is considered as 4 from above equation d 2 = 4.60mm ………………..B According to above both equation, The diameter of secondary shaft is selected as 20mm for safe design.

According to M.S.S. theory,

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Te is 115097 N-mm Me is 82948 N-mm Ϭ = 105 < 150 N/mm2

So, here we have checked the allowable shear stress and bending stress. All values are in limit. and hence it can be considered as a safe design.

4.5 Bearing Selection For spur gear drive, axial load is negligible.

Hence, deep groove ball bearings are suitable for this type of gear box.[8] 4.6 Bearings for Pinion Mounted shaft Designed gearbox is used in rotating calcination drum. The proposed calcination drum machine is supposed to be used for eight hours per day. Therefore, the life of the bearing is taken as 15000 hours. Therefore,

4.7 Equivalent Dynamic Load (P)

The existence of the bearing in million revolutions is calculated as below:

Therefore, dynamic load ability, p - 3 for ball bearing

For a shaft of diameter 20mm,

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Table 1 Location Designation drive shaft 61804

Referred from page no 324 SKF catalogue Single row deep groove ball bearings

4.8 Key Design 4.8.1 Material selection For this application, square sunk key is used. In this type of key, the power transmitted is due to shear resistance. It also prevented relative motion between the shaft and the pulley. These types of shafts are made up of medium with carbon content in between 0.20 to 0.45%. These are nothing but machinery steels.[10] For key design, 30C8 is used [10].

Sut = 610 N/mm2, Syt = 400 N/mm2, o

Design of Key used for Pinion and input shaft

Permissible compressive stress

Permissible shear stress According to m.s.s. theory,

The torque acting on input shaft is given by

4.9 Key Dimensions In industrial field, the dimensions of square key are taken as one quarter dimension of that corresponding shaft.

Therefore,

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Shear stress in the key is given by

Also, crushing stress in the key is given by

The minimum length of the key should be 0.5mm. it is taken as 70mm. [8] V-Belt Drive has widest industrial applications. These belts have trapezoidal cross section. It does not have any joints. Hence, these types of belts are produced only for definite standard lengths. These belts require V shaped grooves pulleys, which are too costly. For power transmission requirement, multiple groove pulleys are used along with number of belts. V-belt drives are mostly suggested for smaller center distances.

But, as compared to flat belt, these drivers are less efficient. V belt transmission ratio is up to 1:15 and belt slippage is very small. If the belts are endless type, V-belt drives do not undergo any joint failure and are discreet in operation. V-belts consist of fabric and cords of cotton, nylon etc. and saturated with rubber. [9]

5. ANALYSIS OF SCREWED SHAFT 5.1 Static Form It consists of steady inertia loads. In this analysis, we have considered loading and response conditions, so that the loads and structure responses changes slightly with respect to time. The various types of loading applied in static analysis contains are: 

External forces, External moments and External pressures.



Gravity and revolving.



Imposed various displacements.

Bearing Support at both ends with X=0, Y=0, Z=0 and Rx=0, Ry=0, Rz=Free

Uniformly distributed load of 1000 N is applied in Y direction on faces as shown

Figure 4: Loading and Boundary Conditions for Static Analysis Figure 4 shows the forces on a support roller shaft in static condition. The load of 100 kg acts on the shaft. Both the ends are kept fixed.

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5.2 Total Deformation plot of Support Roller Shaft

Figure 5: Total Deformation of Screwed Shaft in Static form.

It indicates that total deformation of support roller shaft due to applied constraint. Maximum deformation shows at red zone. Most of the deformation occurs at middle region at which roller has placed. Various color shades denotes values of deformation. The Value of deformation obtained due to analysis is 0.014mm.

5.3 Stress Plots of Support Roller Shaft

Figure 6: Von Mises Stresses in Shaft in Static Condition From the analysis, result, it is found that the maximum stress is 6.8 MPa. Maximum stress occurs at red zone is shown in the above figure 6.

Figure 7(a): Maximum Principal Stress in Shaft in Static condition

Figure 7 (b): Maximum Principal Stress in Shaft in Static condition that the maximum principal stress is 7.4 MPa.

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5.4 Dynamic Form

Figure 8: Loading and Boundary Conditions for Dynamic Analysis 5.5 Total Deformation Plot of Support Roller Shaft

Figure 9: Overall Deformation of Screwed Shaft in Dynamic Form Here Overall Deformation is 0.04 mm.

5.6 Stress plots of Support Roller Shaft

Figure 10: Von Mises Stress in Shaft in Dynamic condition

The area of stress concentration is denoted as red zone. From plot, it is found that the maximum stress is 11MPa. Impact Factor (JCC): 8.8746

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5.7 Maximum Principle Stress in Shaft in Dynamic condition

Figure 11: Maximum Principle Stress in Shaft in Dynamic condition

The exaggerated view of region where maximum principle stress occurs is shown in figure 11. The maximum principle stress is 10 MPa. The red band (shown in exaggerated view alongside) shows the stress concentration zone. The high amount of stress occurs at that region where abrupt change in cross section of shaft. The different colors indicate various amount of concentration of stress.

6. ANALYSIS RESULTS

Sl. No 1

Table 2: Shaft Analysis Results in Static condition Deformation (mm) V-M Stress(MPa) Principal Stress(MPa) 0.014 6.8 7.4

Sl. No 1

Table 3: Shaft Analysis Results in Dynamic condition Deformation (mm) V-M Stress(MPa) Principal Stress(MPa) 0.04 11 10

7 CONCLUSIONS 

In this work, design of the critical components of Corn chaff peeling machine and their assembly is due to extreme loading conditions.



It has simple structure and easy operating process, so that single unskilled operator can also operate this machine.



With regard to safety, this work is more secured than manual methods, as operator does not come direct contact with peeling process.



Material handling is very less for this work.

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Abdulkadir Baba Hassan, Matthew Sunday Abolarin, “The Design and Construction of Maize Threshing Machine”, Department of Mechanical Engg, Federal University of Technology, Nigeria (Jan 2009), pp-199-205.

2.

Anirudha G. Darudkar, Dr. C. C. Handa “Design Consideration of Corn Sheller Machine” IJIRST, ISSN-2349-6010, vol-02, Issue-02, July2015, pp-112-117

3.

Mr. Abhijeet Y. Kedge, Mr. Arjun B. Mane,“A design of compact peeling-shelling machine”, IRJET, ISSN-2395-0056, vol-04, Issue-04, Apr2017, pp-1148-1155.

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Oriaku E. C, Agulanna C. N, Nwannewuihe H. U, Onwukwe M. C And Adiele, I. D “Design and Performance Evaluation of a Corn De-Cobbing and Separating” American Journal of Engineering Research, ISSN-2320-0847, vol-03, Issue-06, pp-127136.

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Anant J. Ghadi and Arunkumar, “Design, development and fabrication of a low cost corn deseeding machine” International Journal of Research in Engineering & Technology, ISSN-2319-1163, vol-03, Issue-08, pp-242-248.

6.

Adewole, C. A., Babajide T. M, “Critical Evaluation of Locally Fabricated Maize Shelling Machine”, IJESIT, ISSN-23195967, vol-04, Issue-02, March2015, pp-67-73.

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Anirudha G. Darudkar, Dr. C. C. Handa, “Literature Review of Corn Sheller Machine” IJIRST, ISSN-2349-6010, vol-02, Issue-01, June2015, pp-238-240.

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KedarPatil “Design and Fabrication of Corn Shelling and Threshing Machine”, IJIRSET, ISSN-2319-8753, vol-05, Issue-07, July2016, pp-13981-13986.

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Mr. Onkar kale, SachitanandKolhe,“Design and fabrication of automatic corn separator machine”, IJARIIE, ISSN-2395-4396, vol-03, Issue-02,2017, pp-1623-1632.

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11. Md. Tanjim Hossain, Md. Mazharul Islam, Mohammad Abdul Jalil, Md. Nasir Uddin & Ayesha Siddika, “The Effect of Different Mordants on Dyeing of Cotton Fabric with Henna”, International Journal of General Engineering and Technology (IJGET), Vol. 4, Issue 4, pp. 1-8 12. E. O Olafimihan, K. A. Adebiyi & S. O Jekayinfa, “Effect of Temperature on The Production of Ethanol Fuel from Selected Agricultural Residues”, International Journal of Mechanical Engineering (IJME), Vol. 4, Issue 6, pp. 51-56 13. N. Deepa, V. M. Indumathi & P. Balaji, “Inventory Management Practices Followed in Coconut Oil Mills in Western Tamil Nadu”, International Journal of Humanities and Social Sciences (IJHSS), Vol. 5, Issue 2, pp. 23-28 14. Parveen Saini & Suraj Choudhary, “Analysis of Machining Parameters for the Optimization of Surface Roughness of Stainless Steel AISI 202 in CNC Face Milling Process”, International Journal of Mechanical Engineering (IJME), Vol. 2, Issue 3, pp.

27-34

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