DESIGN AND ANALYSIS OF

COCOA CUTTING MACHINE

DEPARTMENT OF MECHANICAL

PREPARED BY, GUIDED BY,

ANIL KUMAR K 1JB16ME006 Ms. RASHMI B J
AZIM ABDUL 1JB16ME011 ASSISTANT PROFESSOR
RAKESH K S 1JB16ME065 MECHANICAL DEPARTMENT
PUNEETH YADAV K 1JB15ME074 SJBIT, BENGALURU-60
 1) INTRODUCTION

• Cocoa plant is a small (4 to 8 m height) evergreen tree. In India, it is mainly cultivated in

Karnataka, Kerala, Andra Pradesh and Tamil Nadu mainly as intercrop with Arecanut and
Coconut. Slowly the area under cultivation is being promoted by many chocolate producing
companies as contract farming. In the survey conducted during the time period 2015-2016, India
produced approximately about 17,200 metric tonnes.

• The beans are ground into powder for making beverages, chocolates, ice-cream, soft drinks, cakes,
biscuits, flavouring agents and other products. Cocoa butter, made from the fat extracted from the
beans, is a stable fat used in the production of cosmetics and pharmaceutical products
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 THE COCOA FRUIT:

The cocoa fruit comprises of the pod or shell, beans or seeds, husk, placenta and mucilaginous pulp
which contains a sweet juice referred to as ‘sweating’. Generally, cocoa pods are oval-shaped and
vary in size. The length is normally between 20 and 32 cm. Its colour ranges from yellow or green to
red or violet. The surface texture is warty and deep furrowed to nearly smooth in most cases. The
husks appear appreciably in thickness. Each bean is surrounded by mucilaginous pulp. The number
of beans per pod is usually between 30 and 40. Each bean consists of two convoluted cotyledons and
is enclosed in the testa. The cotyledon has its colour varying from white to purple. Figure shows the
cocoa fruit, beans with the pulp, as well as the pod or the husk.
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 Objectives
• The 3-D Design of the cocoa bean separator is developed by using SOLID EDGE AND CATIA
software.

• The Analysis of the cocoa bean separator.

• using ANSYS WORKBENCH 14 software.

• To make the device user Friendly.

• To make the force minimum for removal of shell.

• To reduce percentage of wastage.

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  THE MACHINE:
Hopper (cocoa inlet)

Crusher and separator

Waste collector

Cocoa seed (output) Support frame

The main objective of the machine is to cut the cocoa pods and to separate cocoa beans from cocoa pods automatically.
THIS MACHINE CONSISTS OF FOUR UNITS.
• Input Unit(loading unit)- Here we put the cocoa pods which is to be cut and separated.
• Cutting Unit- In this unit we cut the cocoa pods in to two parts vertically using rotating blades .
• Rotating Unit(separating unit)- The braked cocoa pods now enters in to a rotating unit where the cocoa
beans get separated from cocoa pod.
• Collecting unit- Here we collect the beans. The innovative approach is given in the cutting
unit. As the cocoa fruit size is varying, the blades are attached by springs. 5
Litreture Survey:
• Analysis on gear teeth by Linhong Xu , Leiming Li , Yin Liu . The operational performance
of gears regarding smoothness, quietness, wear and life span is largely affected by how
gear and pinion teeth make contact. And the geometric characteristic of teeth profile
plays a very important role in influencing contact condition during gear transmission. For a
nominal involute gear pairs, load concentration on the conjugated teeth would be
generated inevitably under the deflection and inclination of gear pairs arising from
topological modification of teeth, manufacturing errors, shaft misalignments and elastic
deflections of the conjugated teeth and support of structure of the gear pair when it is
under load. In this paper, a kind of modification of teeth profile, crowned teeth, is
presented and analyzed by using ANASYS. This work was directed towards investigating
the inherent characteristics of drum-shaped size and stress on the conjugated teeth.
Analytic results are presented to demonstrate the better performance of crown gear
under heavy load in gear transmission and the relationship between drum-shaped size
design and load.

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• Contact Stress Analysis on Composite Spur Gear using Finite Element
Method by Gaurav Mehta ,Mayank Somani ,T.Narendiranath Babu ,
TushitWatts. The contact stress in the mating gears is the key parameter
in gear design. Deformation of the gear is also another key parameter
which is to be considered. Gears generally fail when the working stress
exceeds the maximum stress. The study in this paper shows that the
complex design problem of spur gear which requires fine software skill
for modeling and also for analyzing. The project aims at the
minimization of both contact stress as well as deformation to arrive at
the best possible combination of driver and driven gear. In this process
comparison of Von Mises Stress, Strain and Total Deformation was done
of a ceramic (Silicon Nitride) with a conventional steel gear as a
substitute in the gear manufacturing industry and the software
programmed was performed in SOLIDWORKS and ANSYS Workbench to
get the best result possible.
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• B. Adewumi and A. Fatusin (2006). Design, Fabrication and Testing of
an Impact-Type Hand Operated Cocoa Pod Breaker The machine
developed during the study is simple and easy to maintain. It was
fabricated using materials sourced locally. It is cheap and affordable.
The drudgery and much time involved in the process of breaking the
cocoa pod with hands could be overcome with the help of the
machine.

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TYPICAL SKETCH OF COCOA CUTTING MACHING

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 MODEL DESIGN
Individual parts:

MESH BLADE CHAIN

 SPUR GEAR

SHAFT

FRAME

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• Complete assembly of a model:

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CALCULATION:

• DESIGN ANALYSIS OF THE HOPPER

Material Selection: AISI 1015 CD, Syt of 320 MPa
Sut of390 MPa
INLET LENGTH (mm) : 800
INLET WIDTH ( mm) : 500
OUTLET LENGTH (mm) : 400
OUTLET WIDTH (mm) : 400
HEIGH (mm) : 700
WALL THICKNESS (mm) : 5

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•SHAFT DESIGN
Power at Shaft 5.5 HP
Material: AIS11020CD, Mild Steel
Ultimate Tensile Stress, Sut = 420 MPA
Yielding Stress, Syt = 352 MPA
Assumptions
Let the service factor Cs = 0.80
Reliability factor Cr = 0.81 (99%)
N = 2.0
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Endurance, Sn’ = CsCrSn
But Sn = 0.4Sut
= 0.4× 420
= 168 N/mm2
Sn’ = 0.8 × 0.81 × 168 = 108.864 N/mm2
Weight of roller = 441.45 N
Therefore, WR = 441.45 N
≈ 0.44 KN

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• GEAR DESIGN
• A pair of spur gears with 200 full depth to drive cutting blades mounted on two
parallel shaft to cut a cocoa pod
• The power source is a gasoline engine (cylinder engine) that drives the pinion at 1500
rpm. The gear rotates at 500 rpm and transmits 5hp. The centre distance is 150 mm
• 1. VR= np/nG = NG/NP
• VR=1500/500 =3
• 2. Specify geometry for the first trial design, let’s start by specifying the diametral pitch
• and the number of teeth in the pinion.
• Pd =12, Np=18 from standard fig and table respectively
• NG=Np×VR=(18)(3)=54
• Dp=25.4Np/Pd =(25.4)( 18)/12=38.1mm=0.0381m
• DG=25.4NG/Pd=(25.4)(54)/12=114.3mm
• Centre distance C=25.4(Np+NG)/2Pd=25.4[(18+54)/2(12)]

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76.2 mm
C does not exceed the one given, therefore the geometry is acceptable
3. The pitch line speed vt=πDpnp/60 =[π(0.0381)(1500)]/60=2.99m/s
4. The transmitted load Wt=746P/Vt=746(5)/2.99=1247.5N 62

5. Qv (AGMA quality no) =6

6. Dynamic factor Kv=0.78
7. Application factor Ka=15.7 (power source, cylinder engine and heavy shock
load)
8. Size factor Ks=1.00
9. Face width F=305/Pd=305/12= 25.4mm=1in
10. Load distribution factor Km
F/Dp=25.4/38.1=0.667 therefore Km= 8.
11. The rim thickness factor, KB =1.00
Np=18 NG=54 Therefore
12. The geometry factor JG= 0.410
The geometry factor Jp=0.270
13. Expected bending stress in the pinion σtp=wtPd/FJp[(Ka ks Km KB)/Kv]
σtP =1247.5(25.4/12)[(1.75)(1)(1.32)(1)] = 1139.8MPa
( 25.4)(0.270) 0.78
14. Expected bending stress in the Gear σtG= σtP (JP/JG)
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σtG =1139.8(0.270/0.410)= 750.6 MPa
Standard reliability and life are satisfactory for this design, therefore no
adjustments are necessary.
We decided to use steel for both gear and pinion then elastic coefficient cp =191MPa
The geometry factor I = 0.102,
Ca= Ka=1.75 63

Cm=Km=1.32
Cv= Kv=0.78
Cs = Ks=1.00
15. Expected contact stress on the surface of the teeth σc=(191) √(CaCsCm/Cv)(wt/FDpI)
σc= (191) √[(1.75)(1)(1.32)/0.78] [(1247.5)/ (25.4)(38.1)(0.102)] =1168.2MPa

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 PROGRESS PLANNING CHART
MONTHS
TABLE
AUG'19 SEPT'19 OCT'19 NOV'19 JAN'20 FEB'20 MAR'20 APR'20 MAY'20
PLANNING

RESEARCH

CALCULATION

DESIGN

ANALYSIS

SIMULATION

RESULTS

PLANNED WORK
MONTH FINISHED
N E E D F O R T H I S M A C H I N E :

1. It takes more time for processing the beans by manual method, it take about 6-8 hrs for cutting and
separating 100 kgs of beans.
2. This process requires labours, so labor cost is high.
3. The risk of safety hazards are high in this process.

 A D VA N TA G E S O F T H I S M A C H I N E :

1. It takes less time.

2. Machine can be operated by the farmer alone, thus reducing labour cost
3. The machine is portable and can be placed anywhere in the farm.
4. The chances of injuries are almost nil.
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 (5) CONCLUSION

• By using this method the farmers work such as cocoa pod splitting and bean extraction can
be reduced to some extent.

• The entire design is automatically operated which will be helpful for small land farmers.
This project consumes less time and saves the money .

• With this cocoa pod splitting and bean extraction machine ,farmer can covers more amount
of fruit than manual method.

• This project also highly ergonomic, environmentally friendly cocoa splitting machine that
will be used by cocoa farmers to increase and boost productivity and enhance the quality of
cocoa products to the highest possible level, devoid of any hazards, dangers, perils or risks.
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THANK
YOU

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