DESIGN OF ANIMAL FEED CHOPPER WITH THE

CAPACITY OF 300Kg/hr

Degefa Woyessa

Oromia Agricultural Research Institute, Asella Agricultural Engineering

Research Center, Asella, Ethiopia.

Corresponding author: [email protected]

Contact Number: +251921341767

 TABLE OF CONTENT

TABLE OF CONTENT ................................................................................................................................

LIST OF FIGURE ..................................................................................................................................... iv
ABSTRACT ................................................................................................................................................
vi
1. INTRODUCTION ...................................................................................................................................
1
1.1. BACK GROUND AND JUSTIFICATION .......................................................................................
1
1.2. Objective of the project ......................................................................................................................
2
1.2.1. General objectives .......................................................................................................................
2
1.2.2. Specific objectives ......................................................................................................................
2
2. MATERIALS AND METHODS ...........................................................................................................
3
2.1. Design procedure/Steps ..................................................................................................................... 3
2.2. Design Aspects ...................................................................................................................................
3
2.3. Design Concept ..................................................................................................................................
4
2.1. 1. Concept generation .................................................................................................................... 4
2.2. Design Requirements .........................................................................................................................
4
2.2.1. Concept
selection ............................................................................................................................ 5
2.2.2. Functional structure.....................................................................................................................
5
2.2.2.1. Overall function ...................................................................................................................
5
2.4.5. Evaluation of Concept of selection design criteria ..................................................................... 7
2.4.5.1. Selection of design criteria .................................................................................................. 7
2.4.5.2. Weighting Evaluation Criteria of the objective tree.............................................................
7
i
 2.4.5.3. Determination of weighting factors of the ending branches ................................................
8
2.4.5.4. Assessment of values and Determination of Overall Values. ..............................................
8
2.4.5.5. Comparing Concept Variants ...............................................................................................
9
2.4.5.6. Showing concept variant result in decision matrix of chopping techniques. .....................
10
2.3. Design Analysis and Main components of Animal feed chopper ................................ ....................
13
2.3.1. Selection of motor consider the design requirements (capacity given 300kg/hr) .....................
13
2.3.2. Design and selection of pulley diameters..................................................................................
14
2.3.2.1. Design of hub .....................................................................................................................
15
2.3.2.2. Determination of pulley weight .........................................................................................
16
2.3.2.3. Determination of torque transmitted by the pulley ............................................................
17
2.3.3. Selection of the drive belt ................................................................................................ .........
19
2.3.3.1. Determination of belt contact angle ...................................................................................
19
2.3.3.2. Determination of belt length ..............................................................................................
20
2.3.3.3. Determination of belt Tensions ..........................................................................................
21
2.3.4. Feeding hopper design ..............................................................................................................
23
2.3.4.1. Determination weight of feeding hopper/feeding table................................ ......................
24
2.3.5. Main frame ................................................................................................................................
24
2.3.6. Design of shaft ..........................................................................................................................
25
2.3.6.1. Shaft subjected to a twisting moment ................................................................................
25

ii
 2.3.6.2. Shaft subjected to bending moment ...................................................................................
26
2.3.7. Design of Gear ..........................................................................................................................
28
2.3.8. Chopper Blade ..........................................................................................................................
29
2.3.9. Housing/ upper cover ................................................................................................................
30
2.3.10. Feeding Roller .........................................................................................................................
30
2.5.12. Chopper rotor with its assembly ............................................................................................. 32
2.4. Working Principle of animal feed chopper ......................................................................................
32
2.5. Measurements ..................................................................................................................................
32
2.5.1. Theoretical and actual lengths of cut ........................................................................................
32
2.5.2. Cutting efficiency ......................................................................................................................
33
2.5.3. Feed Chopper capacity ..............................................................................................................
33
2.6. CAD DRAWING OF THE PARTS AND ITS ASSEMBLY ..........................................................
34
2.7. Methods of manufacturing for each part and assembly ...................................................................
40
2.8. Materials Used For Construction ...................................................................................................
41
2.9. Technical Specifications of animal feed chopper ..........................................................................
42
2.10. Estimation of production costs ................................................................................................ .......
42
2.10.1. Direct Material Total Cost ......................................................................................................
43
2.10.2. Operation Cost ........................................................................................................................
44
2.10.3. Cost summary of the animal feed chopper without Engine ................................ ....................
45
3. CONCLUSION AND RECOMMENDATION ..................................................................................
46

iii
REFERENCE ............................................................................................................................................
47
APPENDIX ................................................................................................................................................
48

LIST OF TABLES ........................................................................................................................................

Table :1.The compiling the end branches.......................................................................................8

Table: 2. Weighted and Un-weighted Overall Values Determination............................................9
Table :3. Satisfaction for achieving the criteria in Percentage.......................................................9
Table: 4. Decision making matrix for feed chopping technique...................................................10
Table: 5. Decision of Matrix for selecting the best power supply devices...................................11
Table: 6. Decision Matrix for selecting the best transmission system..........................................11
Table: 7. Materials used for construction.....................................................................................41
Table: 8.Technical Specifications of animal feed chopper...........................................................42
Table: 9.Cost summary of the animal feed chopper without Engine............................................45

iv
 LIST OF FIGURE
Figure 1.Functional structure ........................................................................................................................ 5
Figure: 2 . Structure of the objective Tree .................................................................................................... 7
Figure 3: Assignment of weighting factor for each criterion ........................................................................
8
Figure: 4 motors /Engine ............................................................................................................................ 14
Figure: 5. Chopper pulley 3D view ............................................................................................................
19
Figure: 6 feeding Hopper 3D view ............................................................................................................ 24
Figure: 7. Main frame 3D views ................................................................................................................ 25
Figure 8: Design of chopper shaft ...............................................................................................................
28
Figure 9: Design of 3D view of Gear ..........................................................................................................
29 Figure :10 . 3D view chopper
blade ............................................................................................................ 29 Figure: 11 . 3D view
housing or upper cover ............................................................................................. 30
Figure: 12 . 3D view of feeding roller ................................................................................................ ........
31
Figure: 13 . 3D view UCP bearing or joint .................................................................................................
31
Figure: 14 . 3D view chopper rotor with assembly .....................................................................................
32
Figure: 15. Chopper rotor .......................................................................................................................... 34
Figure: 16. Main frame .............................................................................................................................. 34
Figure: 17. UCP bearing ............................................................................................................................ 34
Figure: 18. Chopper shaft .......................................................................................................................... 34
Figure: 19. Feeding roller .......................................................................................................................... 34
Figure: 20. Chopper blade ..........................................................................................................................
35
Figure: 21. Rotor with blade assembly ...................................................................................................... 35
Figure: 22. Inlet top cover ..........................................................................................................................
35
Figure: 23. Inlet ..........................................................................................................................................
35
Figure: 24. Bolt and nut ............................................................................................................................. 35

v
Figure: 25. Feeding hopper/inlet assembly ................................................................................................
36
Figure: 26. Gear ......................................................................................................................................... 36
Figure: 27. Pulley .......................................................................................................................................
36 Figure: 28. Hinge flange 1 .........................................................................................................................
36
Figure: 29. Hinge flange2 .......................................................................................................................... 37
Figure: 30. Pulley guard .............................................................................................................................
37
Figure: 31. Outlet ....................................................................................................................................... 37
Figure: 32. Hinge pin ................................................................................................................................. 37
Figure: 33. Enclosure main front inlet panels .............................................................................................
38 Figure: 34. Enclosure main side panels ......................................................................................................
38
Figure: 35. Electronic enclosure ................................................................................................................ 38
Figure: 36. Enclosure main front panels ..................................................................................................... 38
Figure: 37. Electronic enclosure mount ..................................................................................................... 38
Figure: 38. Guard mount ............................................................................................................................
38
Figure: 38. Feed chopping assembly ..........................................................................................................
39
Figure: 39. Main assembly of animal feed chopper without pulley guard .................................................
39
Figure: 40. Main assembly of animal feed chopper with pulley guard ................................ ......................
39

vi
 ABSTRACT

Agriculture is the backbone of Ethiopia economy income directly or indirectly and most of its
population is residing in rural areas. The majority of rural community is engaged in agricultural
crop production, cattle farming and poultry production. To prepare feed for animals, the
conventional feed cutting machines are intensively used which do not have friendly operation.
Chopping of animal feed is considered as a labour intensive processing operation in animal
production system. Traditionally, animal feed, especially crop residue are chopped manually by
a sickle in the farms of Ethiopia. It is a labor intensive, less efficient and time consuming
operation. Keeping in view, the drawbacks of the traditional chopping, this study has been
carried out for the design animal feed chopper machine in order to reduce the above mentioned.
Engine operated animal feed chopper has been designed for chopping of crop residue and hay.
The machine was designed with the following main components: feeding hopper, feed roller,
rotating blade, casing with fixed knives welded on it, a screen and stands. The machine was
seated treatment based on the design concepts and designed up to capacity 300 kg /hr. This
machine was design keeping in view its multifunctional operation like for the cutting of maize
stacks, sorghum stack, agricultural crop biomass etc. The provision was provided to run this
machine at variable speeds for different jobs/applications and to achieve variability in particle
sizes. The economic production of designed animal feed chopper machine was simple and its
cost 10,618.45EBirr.

vii
Key words: Design concept, Animal feed, Chopper, Silage making,

viii
 1. INTRODUCTION

1.1. BACK GROUND AND JUSTIFICATION

Ethiopia has higher livestock population than any other country in Africa. According to
Alemayehu (2002), livestock production contributes up to 80% of farmers’ income and about
20% of agricultural GDP in Ethiopia. Besides this, the increase in human population and
decrease in land productivity results in the increase in demands for arable land. For this reason,
scarcity of animal feed and inadequate grazing land are the major problems in the country.

It is needless to say in Ethiopia, traditionally livestock are mainly dependent on natural pasture
and crop residue. Therefore grazing is the common practice in the country. The grazing situation
is exacerbated by the high density of cattle, with stocking rates of four times the recommended
levels being reported in certain areas. This results in the decrease in livestock feed, both in
quality and quantity, in the latter part of the dry season. Usually residues from cereals are the
main sources of feed, but these are low in nutrient content, and have poor digestibility and
palatability. For this reason, livestock tend to lose their weight, and this, in turn, leads to the
decrease in market value, draft power output, disease resistance and amount of milk from milkin
g cows.

In recent years, many farmers are engaged in fattening activities because of the opening of some
livestock commercial channels to other countries, and also there is a great demand for local
consumption. Therefore this activity needs more attention to get a better return from the sector.
In addition, in some parts of the country, there is a long dry season, while in the other part there
is a bimodal rainfall pattern with two relatively short dry seasons. One of the options to
overcome a feed shortage during these dry seasons is to preserve excess fodder grown in rainy
season in the form of silage.

In Ethiopia, fodder making has never become a common practice. This is because without
chopping compacting the material is difficult; and chopping is done manually with hand tools
and so it consumes more labor. Therefore, to make silage making attractive to farmers, chopping
should be simple to apply and not too labor-intensive. In addition to assisting compaction during
silage making, chopping has a great advantage in silage making to increase the surface area to
volume ratio of fodder to facilitate the fermentation process by making free the cell juice and
1
expelling the air. As stated above, farmers in Ethiopia use farm residues of cereals as a feed
source during the dry season. This residue has low palatability; to increase the palatability,
farmers in Ethiopia can practice manual chopping, but it is too labor intensive.

Even though Ethiopia has a huge number of livestock population, the economic productivity is
minimal than technically possible. Among the many factors which contribute to this low
economic productivity, feed shortage is the one. Whether other factors are favorable or
unfavorable for livestock production, the availability of feed greatly affects the livestock
productivity. Therefore, to increase the productivity of livestock, there has to be a means to
alleviate feed shortage during the latter part of the dry season. Silage making when fodder is in
excess and chopping farm residues to use as a supplement of livestock feed are the options. But
the non-availability of an attractive chopping mechanism, for farmers to make silage and chop
farm residues, poses a challenge. Hence the objective of this project was to design of animal feed
chopper with the capacity of 300 kg/hr to assist farmers in silage making and chopping farm
residues to use as feed for livestock.

1.2. Objective of the project

1.2.1. General objectives

 To design of animal feed chopper with the capacity of 300 kg/hr

1.2.2. Specific objectives

 To develop function structure component parts of the chopper

 To prepare 3D and 2D drawing of the chopper
 To prepare exploded drawing of chopper machine

2
2. Materials and Methods

2.1. Design procedure/Steps

This project study was carried out after studying different research reports. Both primary and
secondary sources of information have been exploited to conduct the study. The design steps
used for animal feed chopper were:

 The gathering required information which is associated with agricultural operation for
chopping systems.
 Lists of design requirement
 The conceptual design of an appropriate system to meet their needs.
 Prepare the selection matrix for each concepts
 Rank the concepts
 Combine the concepts to make one product concept
 Select one or more products concept
 Using objective tree analysis, select one best product concept and analysis for each parts
 Modeling (using Solid work).

2.2. Design Aspects

The main design aspects considered during chopper development were cost and complexity of
fabrication, energy requirement, ergonomic factor, maintainability, material strength, kinematics
and style. Considering these design aspects tangential feed type chopper (hammer mill), without
blowing fan and conveyor, was selected for this project. The machine is based on the principles
of hammer mill by which size reduction is accomplished by the cutting effects of rotating knives
against small stationary knife plates welded in the casing. Since the knives are swinging there is
less likelihood of risk even if hard inert material accidentally gets into the chopping chamber.
Feed enters into the chamber from the top of the chopper, and size reduction is done by the
rotating knives; and finally, the output is discharged from the bottom of the machine. The knives
cut the stover and other residue until they become small enough to pass through the bottom
screen. Fineness of chopping is controlled by the screen size. It is obvious that the smaller the
screen size, the more work will be required to reduce the particles to the desired size. Generally,

3
the technology is simple in construction and easy to manipulate, and the replacement of parts
does not cost much.

2.3. Design Concept

2.3. 1. Concept generation

The concept generation process begins with a set of customers need and target specification and
results in a set product concepts from which we make the final specification. Introducing low
cost automation was to overcome problems with the current manual or traditional method. In this
mechanism there are a numbers of uncertain chopping machines such as hand operated chop.
The concept of the work is,

 Observe the manual methods to identify the important process variables.

 Quantify the important method
 Investigate all areas of automated forming.
 Produce a specification for a low cost automated system.
 Refined design of the machine, as this plays a major role in rural area. The above
considering point we can design the semi-automated machine which replace manual
process.

2.4. Design Requirements

The system was more probably chosen search for by fulfilling the following general design
requirement.

 Simplicity of technology
 High efficiency with its capacity of 300kg/hr
 Low maintenance and repair cost
 Small in size to transport from place to place
 Less number of component
 More accurate system as possible
 Safe and easy to operation
 Low manufacturing cost
 Easy to assemble and Maintainability and also power sources
4
2.4.1. Concept selection

Concept selection is process of evaluating concepts with respect to customers need and other
criteria, comparing the relative strength and weakness of the concepts for further investigation,
testing, or developing.

2.4.2. Functional structure

2.4.2.2. Su - b function

5
Material Feeding the Start the Pack the
Chopping the
material to be operation material chopped Energy
Energy
chopped material

Remove un-chopped
material
2.4.2.3. Option Selection of the concept

The following possible alternative options will have deal in the variant evaluation. After
constructing the decision tree the system may follow the shaded region as follow. The selection
was based on the availability source and simple system.

The option selection of the concepts was:

 High efficiency, Simplicity of technology and economy concept

 Animal feed chopping techniques (traditional, manual and engine operated chopping
system) and
 Selection of power sources (A= Generator, B= Solar energy, C= Engine and D= Manual
operation)
 Power transmission system (V- Belt driving, gear driving , chain and sprocket )

Table:-1. Selective system option

Required Generator Solar energy Engine Manual operation

power

Chopping Tradition Manual Engine method

techniques method method

Power supply Chain and Gear driving V- Belt driving

system sprocket

Feeding system Belt convey Manual Gravity and vibration

feeding

6
 2.4 5. . Evaluation of Concept of selection design criteria
2.4.5.1. Selection of design criteria

High efficiency, Simplicity of Technology and Economy

Simplicity of technology High efficiency Economy

Ease of Ease of
assembly manufacturing
Ease of Low maintenance
operation and repair cost
Ease of maintenance

Low manufacturing
Durability
cost

Ease of corrective Ease of preventive

maintenance
maintenance

Figure: 2 . Structure of the objective Tree

2.4.5.2. Weighting Evaluation Criteria of the objective tree

According to the weighting evaluation putting assigning of weighting factors for each criterion
by overall “O” letters. Weighting evaluation based on the structure of the objective tree

7
Figure 3: Assignment of weighting factor for each criterion

2.4.5.3. Determination of weighting factors of the ending branches and Compiling in

Table 1: The compiling the end branches
No End branches Sub weighting factor Overall weighting factor
1 O111 0.25 x 0.4 0.10
2 O1121 0.4x0.3x0.4 0.048
3 O1122 0.6 x 0.3 x 0.4 0.072
4 O113 0.45 x 0.3 x 0.4 0.054
5 O121 0.45 x 0.3 0.135
6 O122 0.55 x 0.3 0.165
7 O131 0.6 x 0.3 0.18
8 O132 0.4 x 0.3 0.12
2.4.5.4. Assessment of values and Determination of Overall Values.

The values are expressed in points of use value analysis approaches by giving 1 for more
important criterion and 0 for less important criterion in a given pair of criteria to be evaluated.

8
Table 2: Weighted and Un-weighted Overall Values Determination
Criteria 1 2 3 4 5 6 7 8 Un weighted Weighted over all
Over all

1 - 1 1 0 1 0 1 0 4 4/28 (0.143 )
2 0 - 0 0 0 1 1 0 2 2/28 (0.071 )
3 0 1 - 0 0 1 0 0 2 2/28 (0.071 )
4 1 1 1 - 1 1 1 1 7 7/28 (0.25 )
5 0 1 1 0 - 0 1 1 4 4/28 (0.143 )
6 1 0 0 0 1 - 1 0 3 3/28 (0.107 )
7 0 0 1 0 0 0 - 0 1 1/28 (0.036)
8 1 1 1 0 0 1 1 - 5 5/28 (0.179 )
Total 28 1
Un-weighted Overall Value was calculated by:
𝑛

𝑂𝑣𝑖 𝑉𝑖𝑗 … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … . … . . . 2.1

𝑗=1

Weighted Overall Value was calculated by

𝑛

𝑂𝑤𝑣𝑖 𝑊𝑉𝑖𝑗 … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … . . . 2.2

𝑖=1

2.4.5.5. Comparing Concept Variants

Table 3: Satisfaction for achieving the criteria in Percentage

Satisfaction (%) Description

100 Excellent, Complete satisfaction, objective satisfied in every aspect

85 Very Good, Extensive satisfaction, objective satisfied in all of important aspect
70 Good, Considerable satisfaction, objective satisfied in the majority of aspects
50 Fair, Moderate satisfaction, a middle point bin complete and no satisfaction
25 Bad, Minor satisfaction, objective satisfied in some but less than half of the
aspect

9
 10 Failure, Minimal satisfaction ,objective satisfied to very small extent

0 No satisfaction, objective is not satisfied in any aspect

2.4.5.6. Showing concept variant result in decision matrix of chopping techniques.

Three animal feed chopping techniques are considered to chop maize stack, sorghum stack with
different range of output within the specified time according to their capacity. These concept variant
are Traditional feed chopping, Manual operated feed chopping and engine operated feed chopping
machine. A = Traditional chopping, B= engine operated chopping machine and C= manual
operated feed chopping.

Table: 4. Decision making matrix for feed chopping technique

Criteria 1 2 3 4 5 6 7 alternative 8 Overall
Satisfaction
𝑜𝑤𝑣𝑖 0.143 0.071 0.07 0.25 0.143 0.107 0.036 0.179
1
A % 25 70 25 10 80 70 70 20

% Owvi 3.575 4.97 1.77 2.5 11.44 7.49 2.52 3.58 32.5
5
B
% 85 80 90 95 65 80 75 90

% Owvi 12.15 5.68 6.39 23.75 9.3 8.56 2.7 16.11 84.68
C
% 80 85 60 75 85 85 50 80
77.8
% Owvi 11.44 6.035 4.26 18.75 12.15 9.10 1.8 14.32

From the table 4 the maximum value of concept variant is 84.68 at B. Therefore Engine operated
animal feed chopping machine was the final selection.

Power supply is one type of the input needed to operate chopper machine. There are four concept
variant are considered to chopping 300 kg/hr within different duration of time according to
capacity of device to generate power. These concept variant are Generator, Solar energy, Electric
motor and manually operated. Let denoting A= Generator, B= Solar energy, C= Engine/ motor

10
 and D= Manual operation. After the result of overall satisfaction is known for each concept
variant then making decision applied.

Table: 5. Decision of Matrix for selecting the best power supply devices
Criteria 1 2 3 4 5 6 7 8 Overall Rank
alternative Satisfaction
𝑜𝑤𝑣𝑖 0.143 0.071 0.071 0.25 0.143 0.107 0.036 0.179

A % 25 25 10 20 30 90 10 40
% * 3.575 1.775 0.71 5 4.29 9.63 0.36 7.16 32.5 4th
Owvi
B % 10 80 50 20 80 40 20 60

% * 1.43 5.68 3.55 5 11.44 4.28 0.72 10.74 42.84 3rd

Owvi
C % 80 95 80 90 85 85 100 80

% * 11.44 6.745 5.68 22.5 12.155 9.095 3.6 14.32 85.535 1st
Owvi
D % 60 80 75 80 75 60 75 70

% * 8.58 5.68 5.325 20 10.725 6.42 2.7 12.53 71.96 2nd

Owvi

Here as shown in the table, the maximum rating is 85.53 and hence concept variant C was
selected as the best concept or alternative. Therefore Engine was the most appropriate power
supply needed to operate animal feed chopping machine.

The other concept variant take into consideration is power transmission system. Power is
transmitted from the motor to elements of the machine by using mechanical devices such as belt,
chain and gear. Denoting A= Belt drive, B= chain drive and C= driving by gear

Table: 6. Decision Matrix for selecting the best transmission system

Criteria 1 2 3 4 5 6 7 alternative 8 Overall Rank
Satisfaction

𝑜𝑤𝑣𝑖 0.143 0.071 0.071 0.25 0.143 0.107 0.036 0.179

11
A % 95 90 75 65 85 75 70 80

% * 13.58 6.39 5.32 16.25 12.15 8 2.52 14.32 78.55 1st

Owvi

B % 70 60 60 70 60 65 70 90

% * 10.01 4.26 4.26 17.5 8.58 6.95 2.52 16.11 70.19 2nd
Owvi

C % 50 70 80 85 70 65 55 40

% * 7.15 4.97 5.68 21.25 10.01 6.95 1.98 7.16 65.15 3rd
Owvi

From this decision matrix, the best concept variant was concept A. It was 78.55; therefore belt
drive was chosen to transfer the power from Engine or motor to the parts of the chopping
machine.

The other concept variant take into consideration is feeding system. Denoting A= manual
feeding, B= belt conveyor and C= gravity and vibration

Table: 7. Decision Matrix for selecting the best feeding system

Criteria 1 2 3 4 5 6 alternative 7 8 Overall Rank
Satisfaction

𝑜𝑤𝑣𝑖 0.071 0.25 0.143 0.107 0.036 0.179

0.071
A % 90 75 65 85 75 70 80

% * 13.58 6.39 5.32 16.25 12.15 8 2.52 14.32 78.55 1st

B Owvi
% 70 60 60 70 60 65 70 90
2nd
C % * 10.01 4.26 4.26 17.5 8.58 6.95 2.52 16.11 70.23
Owvi
% 50 70 80 85 70 65 55 40
3rd
% * 7.15 4.97 5.68 21.25 10.01 6.95 1.98 7.16 64.15
Owvi

12
From this decision matrix, the best concept variant was concept A. It was 78.55; therefore
manual feeding as w chosen in terms to economic visibility of the chopping.

2.5. Design Analysis and Main components of Animal feed chopper

Animal feed chopper was driven by motor and makes the driving of main shaft by belt. Under
the high-speed rotation with cutter making the feed become filiform and powder, the feeds will
be outflow from the material outlet through outlet parts of the chopper. Feed chopper are made
up of feeding part, Cutting and throwing part, transmitting part, and safety device, so it was
reasonably structured safe and reliable. o Feeding part is feed rollers. o Cutting structure made
up of motion knife and locking bolt. o Transmitting structure mainly consist of belt, gears,
pulleys

2.5.1. Selection of motor consider the design requirements (capacity given 300kg/hr)

From the literature survey known that the torque of the motor must be between 30-80Nm was
sufficient for feed chopper. For this project the selected net torque 50Nm and speed requirement
240rpm. Therefore, the Power requirement for the animal feed chopper was calculated by the
following formula.
𝟐𝝅 𝑵 𝑻
𝒑 … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … . 𝟐. 𝟑
𝟔𝟎

Where, p = power, kW
N= number of revolution (rpm)
T = torque, Nm
𝟐𝝅 𝟐𝟒𝟎 𝟓𝟎
𝒑
𝟔𝟎
= 1.25 kW, therefore we have to select 2 HP = 2×0.746 = 1.5 kW was sufficient.

13
 Figure: 4 motors /Engine

2.5.2. Design and selection of pulley diameters

The pulleys used in the drive system were made of cast iron. Pulley diameters were selected
based on the need to reduce the engine speed to the required one. The pulleys must be in perfect
alignment in order to allow the belt to travel in a line normal to the pulley faces. The pulleys may
be made of cast iron, cast steel or pressed steel, wood and paper. The cast materials should have
good friction and wear characteristics. The pulleys made of pressed steel are lighter than cast
pulleys, but in many cases, they have lower friction and may produce excessive wear (Sharma
and Mukesh, 2010). In our case the pulleys are generally made of cast iron, because of their low
cost. The rim is held in place by web from the central boss or by arms or spokes. The following
equation was used to determine pulley diameters.

𝑵𝟐 𝑫𝟏
= … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … (2.4)
𝑵𝟏 𝑫𝟐

Where: N1 and N2 are rpm of driving and driven pulleys;

D1 and D2 are diameters of driving and driven pulleys

The pulley diameter 𝑑1 = 𝑑2𝑤 = = 135𝑚𝑚, where, Therefore, the standard diameter of pulley

D1= 180mm.

14
Let the diameter of the smaller pulley
D2 = D1/2 = 90mm.

If the width of the belt is known, then the width of the pulley or face of the pulley is taken 25%
greater than the width of belt. Therefore, the width of pulley was calculated by:

𝑤𝑝 𝑤𝑏 13𝑚𝑚 … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 2.5

50𝑚𝑚 13𝑚𝑚 63𝑚𝑚

For single belt the diameter of the pulley (D) in mm, the thickness of the larger pulley was
calculated by:

𝑡 𝐷1
3𝑚𝑚 … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … . . . 2.6
200

3𝑚𝑚 3.9𝑚𝑚
The thickness of smaller pulley 𝑡 𝐷2
3𝑚𝑚 200

3𝑚𝑚
3.45𝑚𝑚

2.5.2.1. Design of hub

The hub of a pulley is one of the most important components part. It gives support to the spokes
and the shaft. The diameter of the hub was calculated using following formula. The outside of the
hub is given by Nisbett and Richard (2011).
D 1.50d 25.00 mm … … … … … … … … … … … … … … … … … … … … … … … … … … . … 2.7

𝐷ℎ 1.5𝑑 25
1.5 30 25
70𝑚𝑚 Where:
D = outside diameter of hub, mm
d = diameter of shaft, mm
The length, L, of hub is given by Nisbett,and Richard (2011)

15
 π d
L … … … … … … … … … … . . … … … … … … … … … … … … … … … … … … … … … … … 2.8
2
𝐿 𝜋
𝑑 𝜋
30𝑚𝑚
2 2

47𝑚𝑚

Let us use two belts in order to increase the speed of the chopper and then we have two pairs of
pulleys. The speed of the first pulley in the twice of the second pulley, take assume N1 =
25.57rpm. Then, the speed ratio was calculated N1= 25.57 rpm, d1 = 180mm, d2 = 90mm
Then the speed of the second pulley N2 can be found the following relation

𝑁2 𝑑1 𝑑1 180
, 𝑁2 𝑁1 25.57 51.14𝑟𝑝𝑚
𝑁1 𝑑2 𝑑2 90

2.5.2.2. Determination of pulley weight

Circular shape was used in the construction of the chopper pulley. The weight of the pulley was
calculated as follows.

𝜋𝑑2
𝐴𝑃 … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … . . . 2.9
4

𝜋 0.182 0.025𝑚2
4

Where, AP area of pulley material

d Diameter of pulley, m

The volume of pulley material was computed using the following equations (ITSI-SU, 2011);

𝑉𝑃 𝐴𝑃 𝑡 … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 2.10

0.025 0.0039𝑚
9.92 10−5𝑚3

16
Mass of pulley material was computed using the following equations. The density of cast iron
pulley (𝜌 = 7200kg/m3 (ITSI-SU, 2011)

𝑀𝑃 𝑉𝑝 𝜌 … … … … … ……………………….………………………………………..…
2.11 −5𝑚3 720𝑚03𝑘𝑔
9.92 10

0.714𝑘𝑔

Weight of pulley material was computed using the following equations (Gat, Uri, 1988)

𝑊𝑝 𝑀𝑝 𝑔 … … … … … … … … … … … … … … … … … … … … … … … … . . … … … … … . . . . . 2.12

Weight of larger pulley, 𝑊𝑝1 𝑀𝑝1 𝑔 0.714𝑘𝑔 9 .81

𝑠2
𝑚
7.004𝑁

Mass of smaller pulley, 𝑀𝑝2 𝜌 𝑣 𝜌 𝜋

4
𝑑2
𝑡 7200 𝜋 0 .092
4 0.00345 0.158𝑘𝑔

Weight of smaller pulley, 𝑊𝑝2 𝑀𝑝2 𝑔 0.158𝑘𝑔 9.81

𝑠2
𝑚
1.55𝑁

2.5.2.3. Determination of torque transmitted by the pulley

A first drive cast iron pulley transmits 96.98W at 25.57rpm. The diameter of largest pulley is
180mm and has smooth straight arms of elliptical straight arms of cross-section in which the
major axis is twice the minor axis. Find the dimensions of the arm if the allowable bending stress
is 15MPa. Mention the plane in which the major axis of the arm should lie. Let b 1 = minor axis,
and b2 = major axis = 2b1
Known that the torque transmitted by the pulley
𝑃 180
𝑇 … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 2.13
2𝜋𝑁

108.7𝑁𝑚

17
 Maximum bending moment at the hub end,

2𝑇
𝑀 ……………………………………………………………………..……………………..
2.13
𝑛
2 108.7𝑁. 𝑚
217.42𝑁𝑚
1
And section modulus,

𝜋
𝑍 2
… … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 2.14
𝑏1(𝑏2 )
32

𝜋 2

𝑏1 2𝑏1 32

𝜋 4𝑏13 𝜋 𝑏13
32 8

Known that the bending stresses, σb

𝑀 217.42 8 103 1739.34 103

15 3 3
𝑍 𝜋 𝑏1 𝜋 𝑏1

1739.34 103
3
3 𝑚𝑚3
𝑏1 36. 93 10
15 𝜋
𝑏1 33.3𝑚𝑚

𝑏2 2𝑏1 2 3.33 66.6𝑚𝑚

A first driven cast iron pulley transmits 96.98watt at 51.14rpm. The diameter of this pulley was
90mm and has full arms of elliptical straight arms of cross-section in which the major axis is
twice the minor axis. Find the dimensions of the arm if the allowable bending stress is 15MPa.

18
 Mention the plane in which the major axis of the arm should lie.
𝜎𝑏 15𝑀𝑝𝑎 15 𝑁/𝑚2 Let
b1 = minor axis, and b2 =
major axis = 2b1
Known that the torque transmitted by the pulley,

𝑃 90 96.98 90 8728.2
𝑇 27.18𝑁𝑚
2𝜋𝑁 2 𝜋 51.14 321.16

Maximum bending moment per arm at the hub end,

2𝑇 2 27.18
𝑀 27.18𝑁𝑚
𝑛 1
And section modulus,
𝜋𝑏13
𝑍 … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 2.15
8
Known that the bending stress, 𝜎𝑏,
𝑀 27.18 × 8 × 103 217.44 × 103
15 = 𝑍= 𝜋𝑏13 = 𝜋𝑏13

217.44 × 103
𝑏13 =
15 × 𝜋
= 4616.56𝑚𝑚3
𝑏1 = 16.65𝑚𝑚
Therefore, 2𝑏1 = 2 × 16.65𝑚𝑚 = 33.3𝑚𝑚

19
 Figure: 5. Chopper pulley 3D view

2.5.3. Selection of the drive belt

V-belt and pulley arrangements were used in this work to transmit power from the engine to the
roller shaft. The main reasons for using the v-belt drive was its flexibility, simplicity, and low
maintenance costs. Additionally, the v- belt has the ability to absorb shocks there by mitigating
the effect of vibratory forces (Khurmi and Gupta, 2005).

2.5.3.1. Determination of belt contact angle

The belt contact angle is given by the following equation (Khurmi and Gupta, 2005).

−𝟏
𝑹−𝒓…… … … … … … … … … … … … … … … … … … … … … … … … … … … … . (𝟐. 𝟏𝟔)
𝝋 = 𝒔𝒊𝒏
𝑳
−1
180𝑚𝑚 − 90𝑚𝑚
𝜑 = 𝑠𝑖𝑛
1203.13
= 𝑠𝑖𝑛−1(0.0748)
= 𝟒. 𝟐𝟗°
The angles of wrap for the smaller and larger pulleys are determined by the following
equation: 𝑹 𝒓 … … … … … … … … … … … … … … … … … … … … … … … … . . 𝟐. 𝟏𝟕
−𝟏

𝜶𝟏 𝟏𝟖𝟎 𝟐𝒔𝒊𝒏
𝑳
−1
180𝑚𝑚 90𝑚𝑚
180 2𝑠𝑖𝑛
1203.13
180 2𝑠𝑖𝑛−1( 0.0748) 𝟏𝟕𝟏. 𝟒𝟐°

20
−𝟏
𝑹 𝒓……………… … … … … … … … … … … … … … … … … … … . . 𝟐. 𝟏𝟖
𝜶𝟐 𝟏𝟖𝟎 𝟐𝒔𝒊𝒏
𝑳
−1
180𝑚𝑚 90𝑚𝑚
180 2𝑠𝑖𝑛
1203.13
180 2𝑠𝑖𝑛 ( 0.0748) 𝟏𝟖𝟖. 𝟓𝟖°
−1

Where: R = radius of larger pulley, mm; r = radius

of smaller pulley, mm; α1 = angle of wrap for the
engine pulley, degree; α2 = angle of wrap for the
roller shaft pulley, degree;
C = is the center distance between the two center pulleys. Therefore, by using the above
equations the determined values of φ, α1 and α2 ere 4.w 290, 171.420 and 188.580 respectively.

2.5.3.2. Determination of belt length

The length of belt appropriate to drive the system was calculated using the equation given below
by Shigley (2001). Assume the distance between driver pulley and driven pulley, 180mm
according to frame structure. Center distance (C) of driven pulleys was given by: C = 90/2
+ 225 + 90/2 = 387 mm

𝝅 𝑫𝟐 𝑫𝟏 𝟐
𝑳 𝟐𝑪 (𝑫𝟏 𝑫𝟐) … … … … … … … … … … … … … … … … … … … … … . 𝟐. 𝟏𝟗
𝟐 𝟒𝑪

𝜋 (180𝑚𝑚 90𝑚𝑚)2
𝐿 (90𝑚𝑚 180𝑚𝑚) 2 387𝑚𝑚
2 4 387𝑚𝑚
423.9𝑚𝑚 774𝑚𝑚 5.23𝑚𝑚
1203.13𝑚𝑚

Where: L = belt length, m;

C = center distance between pulleys, m;

21
 D2 = pitch diameter of driven pulley, m;
D1 = Pitch diameter of driver pulley, m.

Since the calculated length of v belt is equal to the closest standard belt the exact center distance
is also correct. Therefore, center distance was equal to 387mm. Speed of the belt was calculated
by using the following equation as given by (R.S.Khurmi and J.K.Gupta, 2005)

𝝅 𝑫𝟏 𝑵 𝟏
𝑽 𝟏 … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 2.20
𝟔𝟎

𝜋 0.18𝑚 25.57𝑟𝑝𝑚
𝟏 1 0.24 1.24 𝑚/𝑠
60

2.5.3.3. Determination of belt Tensions

Power requirement for animal feed chopper was 1.5 kW. As losses in between pulley
arrangement is considered, i.e., such that belt pulley power transmission efficiency is 85-95%. To
determine tensions on the tight and slack sides of the belt the following equations was used
(R.S.Khurmi and J.K.Gupta, 2005). Calculate belt tension and width: Design a rubber v-belt to
drive a machine with 96.98W at 25.57 rpm and fitted with a pulley 180mm diameter. Allowable
stress for belt, 𝜎 2.1𝑀𝑝𝑎 2.1 106 𝑁⁄𝑚2
Density of rubber, 𝜌 1000 𝑘𝑔⁄𝑚3 = 1000 kg / m3 Angle of

contact driver pulley, 𝜃 165° 165 𝜋

2.88𝑟𝑎𝑑
180

Coefficient of friction between belt and pulley, 𝜇 0.3

Power transmitted (P)

𝑃 (𝑇1 𝑇2) 𝑉 … … … … … … … … … … … … … … . . … … … … … … … … … … … … … … … … 2.21

96.98𝑤 𝑇1 𝑇2 1.24 𝑚⁄𝑠

96.98𝑤
𝑇1 𝑇 2 1 .24 𝑚⁄𝑠 78.2𝑁 … … … … … … … … … … … … … … … … … … … … … … . … … … .
2.22
22
We Know that,
𝑇1
2.3 log 𝜇 𝜃
𝑇2
0.3 2.88 0.864𝑟𝑎𝑑

log 𝑇1 0.3756𝑟𝑎𝑑
𝑇2

𝑇1
2.375𝑁 … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … . 3.23
𝑇2
From equations (3.22) and (3.23),
𝑇1 135.1𝑁

𝑇2 56.87𝑁
Let b= Width of the belt in meters, and t = thickness of the belt in meters. Assuming thickness of
the belt, t= 10 mm = 0.01 m, cross-sectional area of the belt
𝐴 𝑏 𝑡 𝑏 0.01 0.01𝑏𝑚 2 The mass

of the belt per meter length, m Area

length density

0.01𝑏𝑚2 1.203𝑚 1000 𝑘𝑔⁄𝑚3 12.03𝑏𝑘𝑔/𝑚

According to R.S.Khurmi and J.K.Gupta, 2005 torsional moment (Tr) due to single belt tensions
was determined using the following equation.

𝑇𝑐 𝑚 𝑉2 … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … . . 3.24

12.03𝑏1.242 18.5𝑏𝑁

The maximum tension in the belt

𝑇 𝜎𝑚𝑎𝑥 𝑏 𝑡 … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … . . 3.25

2.1 106 𝑏 0.01

23
 21000𝑏𝑁
And tension in the tight side of belt (T2),

56.87𝑁 𝑇 𝑇𝐶
21000𝑏𝑁 18.5𝑏𝑁
20981.5𝑏𝑁

𝑏 56.87𝑁
0.0435𝑚 43.5𝑚𝑚. Therefore, the standard width of the belt b is 50 mm.
20981.5𝑁
Where: Tc and T= the centrifugal and maximum tension of the belts (N);
T1 and T2 = tension in the tight and slack sides (N); σmax=
maximum safe normal stress (N/mm2); m = mass per unit length
of belt (kg/m) and v = is speed of belt (m/s).

2.5.4. Feeding hopper esignd

Hopper, use as a feeding unit is part of animal feed chopping machine that serves material cutting
into the blade housing. The cutting material is fed manually through the hopper from the top side.
Hopper or Feeding Trough is used to feed fodder such as maize stack, cutting grass etc. Hopper
decides capacity of feed cutter. The main purpose of hopper is providing direction to fodder and
bring contact with cutting blade. The hoppers house the materials and deliver the materials to the
feed roller at regulated feed rate. The hopper has a shape which facilitates loading, maximum
volume utilization and reliable and complete gravity discharge through its outlet. The volume of
the hopper was calculated by the following equation:

h
𝑉 𝐴1 𝐴2 𝐴1𝐴2 … … … … … … … … … … … … … … … … … … … … … … … … … … . . 2.26
2
𝐴1 354 𝑚𝑚 152𝑚𝑚
53,808 𝑚𝑚2
𝐴 2 270 𝑚𝑚 98𝑚𝑚
26,460 𝑚𝑚2

460 𝑚𝑚
𝑉 53,808𝑚𝑚2 26,460𝑚𝑚2 53,808𝑚𝑚2 26,460𝑚𝑚2 2

24
 𝑉 0.00143𝑚3
Where, V= volume of hopper, mm3, h = height, 460(mm)
A1 = base area of truncated cone, top of hopper, mm2
A2 = base area of truncated cone, bottom of hopper, mm2
2.5.4.1. Determination weight of feeding hopper/feeding table

Trapezoidal shape was used in the construction of the animal feeding hopper. The weight was
calculated as follows. Mass of feeding hopper material was computed using the following
equations (ITSI-SU, 2011)

𝑀𝐹 = 𝐴𝐹 × 𝑡 × 𝜌𝑓 … … … … … … … … … … … … … … . … … … … … … … … … … … … … … … (2.27)
𝑀𝐹 = 0.08 𝑚2 × 1.5 × 10−3𝑚 × 7850𝑘𝑔/𝑚3

𝑀𝐹 = 0.945 𝑘𝑔
Weight of feeding material was computed using the following equations (Gat, Uri, 1988)

𝑊𝐹 = 𝑀𝑓 × 𝑔 … … … … … … … … … … … … … … … … … … … … … … … … . . … … … … . . . (2.28)

= 0.945 𝑘𝑔 × 9.81𝑚/𝑠2
= 9.272 𝑁

25
 Figure: 6. eeding fHopper 3D view
2.5.5. Main frame

Main frame is generally consists of four legs and made up of angle iron .The whole machine was
mounted over the legs. The minimum height of the stand is approximately 550mm from the
ground level for easy feeding of the crop in standing posture of the user. All detail dimension was
described under the appendix, only the isometric view was drawn in the below figure.

Figure: 7. Main frame 3D views (all dimension in mm)

2.5.6. Design of shaft

This shaft made up of mild steel carbon which is use for fitting the pulley and transmitting the
motion of the feeder roller through the worm and gear. The main shaft was strictly attached with
the pulley in its center whereas the other end is supported on a block through bearings. The
length and diameter of the main shaft was calculated below. The shafts were designed on the
basis of strength rigidity and stiffness. In designing shafts of the basis of strength, the following
cases may be considered that is the shaft will be designed by considering the following.

2.5.6.1. Shaft subjected to a twisting moment

26
 To find the diameter of the shaft when the shaft was subjecting moment (torque) only

𝑇 𝜏
= ………………………………………………………………………………………………
(2.29)
𝐽 𝑟

Where: T = Twisting moment or torque acting on the shaft.

J = Polar moment of inertia of the shaft about the axis of rotation.
𝜏 = Torsional shear stress and r = Diametric distance
from neutral axis to the outer most fiber.

The allowable shear stress for the shaft material was calculated as

𝜎𝑢
𝜏 ……………………………………………………………………………………..……..
(2.30)
2𝑓𝑠

560𝑀𝑝𝑎

2 ∗ 3.5
560𝑀𝑝𝑎
𝑀𝑝𝑎
Where, 𝜎𝑢 560𝑀𝑝𝑎 for carbon steel
fs = factor of safety 3.5
From the equation

3
𝜋 … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … . 2.31
𝑇𝜏∗𝑑
16

The diameter of the shaft by considering twisting of the shaft

𝜋 𝜋 50000 ∗ 16

𝑇 𝜏 𝑑3 50000𝑁𝑚𝑚 ∗ 80 ∗ 𝑑3, 𝑑3 , 𝑑 14.27𝑚𝑚

16 16 80 ∗ 𝜋

27
 2.5.6.2. Shaft subjected to bending moment

When the shaft is subjected to bending moment only, then the maximum stress was given by

𝑀 𝜎𝑏
… … … … … … … … … … … … … … … … … … … , … … … … … … … … … … … … … … … 2.32 𝐼
𝑦

Where M = bending moment

I = moment of inertia of cross sectional of shaft
𝜎𝑏 = bending stress
y = distance from neutral axis to the outer most fiber
For round solid shaft, moment of inertia is found by 𝐼 𝜋 𝑑4
and 𝑦 𝑑
substitution in equation (3.32)
2

𝑀 32 𝜋 ∗ 𝜎𝑏 ∗ 𝑑3 … … … … … … … … … … … … … … … . … … … … … … … … … … … … … … . 2.33
The maximum bending moment of the carbon steel was, M = 424320Nmm. Substituting the
above values to determine diameter of the shaft

𝑀 𝜋𝑑3

424320𝑁𝑚𝑚 𝜋𝑀𝑝𝑎 ∗ 𝑑3
∗
𝑑 27013.05,
𝜋 ∗ 160
𝑑 𝑚𝑚
Therefore, for the design we should have to taking the maximum of the two 30mm 14.27mm,
the diameter of the shaft was , d = 30mm.
Mass of shaft was calculated by the following equation

𝑀 𝜌 ∗ 𝑣 … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … . 2.34

Shaft made up of carbon steel with density of 7853kg/m3.

𝜋𝑑2

28
𝑣 𝐴∗𝐿 𝐿
𝜋 ∗ (0.03)2 ∗ 0.7

4
4.95 10 𝑚3
−4

Mass of shaft material was computed using the following equations (Gat, Uri, 1988)

𝑀𝑆 4.95 10−4𝑚3 7850𝑘𝑔/𝑚3

3.885 𝑘𝑔
The weight of the shaft was estimated using the following equations

𝑊 𝑠 𝑀𝑠 𝑔
𝑊𝑠 3.885 𝑘𝑔 9.81 𝑚/𝑠2
38.12 𝑁

Figure 8: Design of chopper shaft

2.5.7. Design of Gear

The gears are used to transmit power .By changing the gear used; the speed can be adjusted to
obtain various cutting lengths. These gears are used to transmit the power from main shaft to
feeding rollers.
Assume that the speed of lower roller was = 55 rpm
Let power transmitted = 1.5 kW
Let take input out- put = 240 rpm
Out -put speed =55 rpm
The gear was made from hard steel material having ultimate bending stresses (𝜎ut=700 N/mm2)
Number of teeth on gears was calculated by the following formula.

29
𝑇2 𝑁1
= … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … . … … (2.35)
𝑇1 𝑁 2
𝑁1
𝑇2 = × 𝑇1
𝑁2

𝑇2 = × 𝑇1, Assume, 𝑇1 = 16 teeth, 𝑇2 = × 16 = 70 teeth

Figure 9: Design o f 3D view of Gear

2.5.8. Chopper Blade

These blades are made up of High carbon steel or alloy steel. The function of the blade is to cut
the silage material that can be chopped into smaller pieces suitable for animal feed. There are
four cutting blades used in this machine.

30
Figure :10 . 3D view chopper blade
2.5.8.1. Estimation of Force required in cutting chopper blade

Estimation of Force required in cutting chopper blade was calculated by the following formula.

𝑭 = 𝑨 × 𝑵𝑺 × 𝑺 … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … . (𝟐.
𝟑𝟔) Where, F = force required in cutting the silage

A = cross section area of individual stem

𝑁𝑆 = number of stem at a time in throat
S = shear strength of material

2.5.9. Housing/ upper cover

Housing covers the cutting sharp edge. Housing protects the person from not touching the cutting
edges accidentally.

31
Figure: 11 . 3D view housing or upper cover

2.5.10. Feeding Roller

There are two feed rollers, upper feed roller and lower feed roller, present in the fodder chopper.
These rollers are made up of cast iron and have teeth on its periphery. The chopped material was
first feed to the rollers, which in turn grip the material and then it move forward to the cutting
blade. The lower feed roller was fix while the upper feed roller is spring loaded which can move
up and down depending upon the quantity of silage being fed.

Figure: 12 . 3D view of feeding roller

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2.5.11. Joints

A joint is a rigid rod that allows the rod to bend in any direction, and is commonly used in shafts
that transmit rotary motion. It consists of a pair of hinges located close together, oriented at 90°
to each other, connected by a cross shaft.

Figure: 13 . 3D view UCP bearing or joint

2.5.12. Chopper rotor ithw its assembly

These are made up of hard metal steel plates. These rotor cts as the a rotating member of the
silage cutting mechanism.

33
Figure: 14 . 3D view chopper rotor with assembly

2.6. Working Principle of animal feed chopper

Engine drives the main shaft with the help of belt drive. Gears, Pulleys and blades are mounted
on the main shaft. Main shaft drives the blade and gears mounted on it. Power was ansmitted to tr
the feeding roller with the help of gear system. Silage was entered through the hopper to feeding
roller. Feeding roller moves the silage to the cutting head. Blades cut the silage into uniform
small pieces and throw the final product outside the machine.

2.7. Measurements

The following items were measured and estimated during evaluating the forage chopper under
the studied parameters:

2.7.1. Theoretical and actual lengths of cut

The theoretical lengths of cut Lth was calculated using the following equation according to
Sankpal, et al., 2017.

60000𝑉𝑓
𝐿𝑡ℎ … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 2.37
𝜆𝑘𝑛𝑐

Where:

Lth = Length of cut, cm

Vf = Feed velocity, m/s (peripheral speed of feeding mechanism);
nc = Cutter head rotational speed, rpm, and 𝜆𝑘 = Number of
knives on the cutter head.

2.7.2. Cutting efficiency

The cutting efficiency of the animal feed chopping was calculated as follows

𝐿𝑡ℎ
Ƞ𝑐 100 … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … . 2.38
𝐿𝑎𝑐

34
 Where, Ƞ𝑐 = Cutting efficiency, %
Lac = Actual length, (mm) and
Lth = Theoretical length, (mm).

2.7.3. Feed Chopper capacity

The theoretical capacity Tth, in ton per hour, was expressed by the following relationship
𝜌 𝑓 𝐴 𝑡 𝐿 𝑐 𝜆𝑘 Ƞ 𝑐
𝑇𝑡ℎ 6 108 … … … … … … … … … … … … … … … … … … … … … … … … … . .
2.39

Where:

𝑇𝑡ℎ = Theoretical capacity, kg/s;

𝜌𝑓 = Density of forage in the thereat, in kg/m3;

𝐴𝑡 = Thereat area, in cm2;

𝐿𝑐 = Theoretical length of cut in mm;
𝜆𝑘 = Number of knives on cutterhead, and
Ƞ𝑐= Speed of cutter head, rpm.

2.8. CAD DRAWING OF THE PARTS AND ITS ASSEMBLY

35
 Figure: 16. Main frame Figure: 15. Chopper rotor

Figure: 18. Chopper shaft Figure: 17. UCP bearing

Figure: 19. Feeding roller

36
Figure: 21. Rotor with blade assembly Figure: 20. Chopper blade

Figure: 23. Inlet Figure: 22. Inlet top cover

37
 Figure: 24. Bolt and nut

38
 Figure: 25. Feeding hopper/inlet assembly

Figure: 27. Pulley Figure: 26. Gear

Figure: 28. Hinge flange 1

39
 Figure: 30. Pulley guard Figure: 29. Hinge flange2

Figure: 32. Hinge pin Figure: 31. Outlet

40
Figure: 34. Enclosure main side panels Figure: 33. Enclosure main front inlet panels

Figure: 36. Enclosure main front panels Figure: 35. Electronic enclosure

Figure: 38. Guard mount Figure: 37. Electronic enclosure mount

41
 Figure: 39. Feed chopping assembly

Figure: 40. Main assembly of animal feed chopper without pulley guard

42
 Figure: 41. Main assembly of animal feed chopper with pulley guard

2.9. Methods of manufacturing for each part and assembly

For constructing of products materials are needed. All these processes used in manufacturing
concern for changing the ingots into usable products it includes as shaping processes, machining
processes, metal forming processes, joining processes, surface finishing processes and processes
effecting change in properties. Therefore, animal feed chopper was manufacturing by the
following method given in tables below:
s/no Components Methods of manufacturing pats
1 Main Shaft facing ,Grinding , boring and turning
2 Feeding hopper Bending, welding and joining
3 F ee d Rolls Casting, rolling and shaping
4 Housing/ upper cover Bending, drilling and joining
5 F ee d roll Shaft Rolling, grinding and slotting
6 Gears Grooving, Casting and shaping
7 Pulley Shaping, Rolling and machining
8 Chopper Blade Grinding , shaping , punching and drilling

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9 Main Frame Sawing, drilling ,cutting, welding and joining
10 Chopper rotor Shaping, rolling,

11 Pulley guard Bending, drilling and joining by bolt and nut

12 Hinge flap Rolling

13 Engine setting Joining by bolt and nut and drilling

14 Outlet Bending, welding and joining by bolt and nut

2.10. Materials Used For Construction

Table: 7. Materials Used For Construction
s/no Components Material
1 Main Shaft Mild Steel
2 Feeding hopper Mild steel sheet metal
3 F ee d Rolls Cast Iron/Mild Steel
4 Housing/ upper cover Cast Iron/Mild Steel
5 F ee d roll Shaft Cast Iron/Mild Steel
6 Gears Cast Iron
7 Pulley Cast Iron
8 Chopper Blade High Carbon Steel
9 Main Frame Mild Steel
10 Chopper rotor Mild Steel

11 Pulley guard Mild steel sheet

12 Hinge flap Mild steel

13 Engine setting Mild steel

14 Motor shaft Mild steel

15 Motor pulley Cast iron
16 Outlet Mild steel

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2.11. Technical Specifications of animal feed chopper

Table: 8.Technical Specifications of animal feed chopper

s/no Type Specification

1 Number of Gear 02

2 Number of rollers 02
3 Number of blades 04
4 Width chopper 1042 mm
5 Height chopper 950 mm
6 Capacity 300 kg/hr
7 Approx. Weight 120 kg

8 Engine speed 240 rpm

9 Types of belt used V-Belt drive
10 Feeding hopper Length 450 mm, Width 250 mm, Height 235 mm

11 Frame 550 mm in long, 430 mm in wide

2.12. Estimation of production costs

In designing and manufacturing a technology, cost analysing is one important factor to assure the
reliability and affordability of that technology. For a given system, the cost of a subsystem
(performing one function) can be estimated from individual components or functional groups.
These costs are added together to give the total system costs. The cost estimating technique starts
from a set of engineering drawings for components of an assembly, and calculates the cost of
each operation involved in component manufacturing, assembling and finishing. To minimize the
cost of manufacturing processes, eliminating unnecessary operations has a great effect on it. This
can be achieved through proper planning, following sequence of operation and grouping of
individual operation or group of operations in succession. Grouping operations has the following
advantages;

45
 o Reduced fixed cost o
Reduced labour cost o Less
handling o Reduced setup
time o Smaller in process
inventory
Depending on the types of manufacturing process, total cost of the designed machine was
determined by considering the following. The main elements of cost analysis includes
o Direct material total
cost o Standard items cost o
Direct Labour cost o
Operation cost

2.12.1. Direct Material Total Cost

To determine the total cost of direct materials used in the manufacture of the animal feed chopper
a material balance and flow sheet should be developed. Once the materials balances established,
raw material prices must be assessed and identified. Therefore the materials and their current cost
needed to manufacture the chopper were studied from the current markets.

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 No Part name Types of material St. specification S.mat.used Unit Qunt. U.price T.price

1 Main frame Sheet metal 4x1000x2000 mm 68cmx83 cm pcs 1 850 640.00

Angle iron 4x1000x2000 mm 55cm 40x cm pcs 4 320 352.00
Electrode 3.25 3.25 pct. 1 100 100.00
Metal bolt &nut M10x35 M10x35 pcs 14 3.5 49.00
2 Chopper shaft Steel shaft 40x6000 mm 75cm pcs 1 1000 925.00
3 Feeding Sheet metal 2 x1500x2000 mm 30x96 cm pcs 1 1800 1600.80
hopper
Bearing house USP 6204 USP 6204 pcs 4 400 1600.00

Pulley 25x175 mm 25x175 mm pcs 2 200 400.00

Metal bolt &nut M8x30 M8x30 pcs 8 3 24.00
4 Chopper blade Sheet metal 4x1000x2000 mm 40cm x50cm pcs 4 150 800.00
5 Housing/ upper Sheet metal 2x1500x2000 mm 42 x 45cm pcs 1 1800 1800.00
cover
Metal bolt &nut M10x35 45 x 40 Pcs 18 4.5 81.00

6 Belt Rubber V- belt A-48 pcs 1 165 165.00

7 Feed roll Shaft Steel shaft 4x6000mm 75cm pcs 2 450 900.00
8 Gears Cast/mild steel psc 2 350 700.00
Sub total 10,136.8

2.12.2. Operation Cost

The machining cost of animal feed chopper considers expenses under part operation including electric consumption, material
transportation; storage cost, machine depreciation cost, assembly and machine maintenance cost, non-production time cost and others
factors.
44
No. Type of operation Machine Working Total L. cost/hr W.hr T.L
cost/hr hour cost cost

1 metal cutting 10.00 50 8.33 9.00 149 22.36

2 Bending 2.87 50 2.39 9.00 461 69.15
3 Welding 5.10 45 3.83 9.00 134 20.1
4 Drilling 2.30 50 2.00 9.00 314 13.61

5 Rolling 2.87 45 2.15 9.00 83 12.45

6 grinding 0.74 22 2.07 9.00 238 35.70
7 Shaping 8.80 45 6.60 9.00 50 7.50
8 Total assembling 0.00 0 0.00 9.00 54 8.10
&checking
Sub total 27.37 190

2.12.3. Cost summary of the animal feed chopper without Engine

Table: 9.Cost summary of the animal feed chopper without Engine

1 2 3 4 5 6

Raw Material Machine Labor Over- head cost Production cost

material wastage 2.5 % cost (Birr) cost(Birr) % 5 of 3 & 4 (1+2+3+4+5)
cost (Birr ) of 1 ( Birr )
Birr

10,136.8 253.420 27.37 190 10.868 10,618.450

3. CONCLUSION AND RECOMMENDATION

Animal feed chopping machine was simple in construction as there is not so much complication
in design. It is also important that velocity ratio can easily be determining measuring number of

49
teeth on gears. The machine was designed in such a way that it was requiring minimum space to
install. As the motor was placed inside the machine stand not outside the machine, the space was
considerably saved. Frame and machine stand, it can be handled safely without injury. Blades
were provided with double sharpening edges. The machine was provided with motor sliding
arrangement and the cutting blades can be easily chopping by operator for sharpening purpose.
Machine has reduced noise and weight due to gears arrangement and compact design. Machine
has casters for portability. It is also noted that the optimum results could be obtained using a
capacity of has 300kg/hr chopping cutting rate. The economic production of designed animal
feed chopper machine was simple and its costs 10,618.45 EBirr.

Recommendations

The following recommendation should be carried on:

 The proposed animal feed chopper machine for feed should be designed and evaluation
to complete the processing of feed production in small productive farms.
 Testing of the designed animal feed chopping machine should be carried out in the actual
field condition for small farms development.

REFERENCE

Anand Kumar. (2016). Design and Modal Formulation of Power Operated Chaff Cutter.
International Journal on Emerging Technologie, 7(2), 181–187.
Bandiwadekar, C., Kamble, A., Vivek, G.Z.S., Patil, D.Y. (2016). Review Paper on Design &

50
 Development of Chaff Cutting Machine
Gat, U. (1988). The weight of mass and the mess of weight.In Richard Alan Strehlow.
Standardization of Technical Terminology, Principles and Practice:ASTM International,
vol (2), pp45-48.
ITSI-SU, January, 26. (2011). Mass, volume and density of regularly and irregularly shaped
object. Internet: <http://www.pdesas.org/module/content/resources/14756/view.ashx>.
Khope, P.B., Modak, J.P. (2013). Design of experimentation for establishing empirical
relationship of chaff cutting phenomenon energized by human powered flywheel motor
Nisbett, R. G. B. and J. K. (2011). Shigley’s Mechanical Engineering Design. ninth edition,
McGra -w Hill, New York, USA.
R.S.Khurmi and J.K.Gupta. (2005). A textbook of Machine Design, 4th edition,Eurasia
publishing house (PVT.) LTD. Ram nagar,New dellhi,India.
Sankpal, N., Powar, V., Patil, S., Salunke, K., & Pandit, P. S. V. (2017). Design and
Modification of Chaff Cutter Objectives : International Journal of Innovative Research in
Science,Engineering and Technology, 5675–5683.
Sharma and Mukesh. (2010). Farm Machinery Design Principles and Problems.1st Edition,Jain
Brothers 16/873, East Park Road, Karol Bagh, New Delhi.

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APPENDIX

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