CHAPTER 1

INTRODUCTION
Banana leaves have a wide range of applications because they are large, flexible,
waterproof and decorative. They are used for cooking, wrapping and food-serving in a
wide range of cuisines in tropical and subtropical areas. They are used for decorative and
symbolic purposes in numerous Hindu and Buddhist ceremonies.

In traditional homebuilding in tropical areas, roofs and fences are made with dry banana-
leaf thatch. Banana and palm leaves were historically the primary writing surfaces in many
nations of South and Southeast Asia. Banana leaves are large, flexible, and waterproof.
They impart an aroma to food that is cooked in or served on them; steaming with banana
leaves imparts a subtle sweet flavour and aroma to the dish. The leaves are not themselves
eaten and are discarded after the contents are consumed.

Banana leaves are used by Hindus and Buddhists as a decorative element for special
functions, marriages, and ceremonies in southern India and Asia Balinese Hindu prepared
banana leaf as the container for floral offerings called canning dedicated for hyang (spirits
or deities) and gods. These floral offerings were placed in various places around the house.

The banana leaf cutting machine is used to produce different shapes of leaf spreads in
faster production rate. The principle of operation is the same as the conventional simple
press. The difference is only in the type of drive and the type of working mechanism used.

1
 OBJECTIVE

To design and fabrication of Banana Leaf cutter by using quick return mechanism.

2
 Chapter 2

LITERATURE REVIEW

Balaji A , JahirHussain H , FaheemAshkar MR , Gowsick C S , Subakar K

Design and Fabrication of Agro-based Automatic Plantain Tree Cutting Machine

This paper deals with the design and fabrication of low cost cutting machine for banana
tree on a large scale. In existing system, the cutting and decomposition process takes much
time and the cost requirement is also high.The mechanical part of the machine consists of
lead screw, journal bearing and cutter blade. High strength lead screw is used to eliminate
the thrust. The cutter blade is designed to rotate at high speed. The electrical system of the
machine contains wiper motor and inductive type proximity sensor. The lead screw
coupled with wiper motor rotates in clockwise direction. When proximity sensor detects
the top position, signal is sent to the relay and reverses the motor direction. During
downward movement cutter blade turned off using multipoint relay. Due to the continuous
motion of the cutter blade and lead screw movement, the banana trees are cut into pieces.
The machine is designed with economic feasibility by including sensors and relays.

Shangkavi G , Jibin Mohan C , Kesavaraj N , Nandhani T , Vijayalakshmi M

Automatic Leaf Picking Machine

In Early days, Labours are used to take the banana leaf in banquet meal. So in order to
reduce human work, the simple mechanism is used to take the leaf automatically by using
Automatic leaf picking machine. The main purpose of this project is to pick the leaf
automatically using the leaf picking machine. Initially in the existing system, the food was
served in banana leaf. At that time banana leaves are picked manually by human beings in
special occasions. Mostly in the function hall, the number of human resources required to

3
collect the leaf is very high, in this type of process the time consumption is also very high.
To overcome this problem, the paper Automatic leaf picking machine is proposed.

Mohanraj K S Vijayakumar P , Senthilkumar R ,GokulKarthik A

DESIGN AND ANALYSIS OF SEMI AUTOMATIC PAPER CUM ARECANUT

PLATE MAKING MACHINE

This paper is mainly focusing on the cutting operation and punching operation are done
independently in the current self-loader areca nut plate making machine. To conquer this,
self-loader areca nut plate making machine joins both activities, which will expand
creation rate. The fundamental concentration of the venture 'Plan and examination of
semi-computerized areca nut plate making machine' is to outline the machine for
assembling of 12-inch areca plate. The primary parts of the machine are upper bite the
dust and lower kick the bucket, engine and warming curl. The working rule of the machine
follows up on water driven constrain. The upper and lower pass on are warmed by
warming curl which is controlled by power. The water driven constrain is instigated in the
machine to move the kick the bucket in vertical movement. As an areca nut leaf sheath is
set between the passes on, the development of the bite the dust causes punching and
cutting procedure in the sheath. The energy of the engine is 2Hp. The water driven weight
is 100kgf/cm2. The stroke length is around 12cm.The current utilization by the machine is
2unit for 8hours. Areca nut plates are accessible in different sizes as per pass on sizes.
These plates are helpful, airtight, light in weight, solid, biodegradable. The venture 'Plan
and examination of areca nut plate making machine lessens the assembling time and
expands the creation requiring little to no effort.

Mahendra K C ,Virupaksha Gouda H

Design and Fabrication of Plantain (BANANA) Fiber Extracting Mechanism

4
Objective of the present paper is to design and fabrication of banana fiber extraction
equipment to develop high quality banana fiber from banana pseudo stems. Banana fiber
offers good mechanical properties. This plant fiber has long been a better source for high
quality textiles industries in many parts of the world, especially in Japan and Nepal.
Manually extraction of the banana fiber requires proper procedure and its time consuming.
Labour expense is also high. Now day’s machines exist for extracting banana fiber with
mass production. The number of machines is currently available nowadays, but quality
obtained is not up to the optimum level. This can be overcome by fabricating the
designing of an extracting mechanism of banana fiber from plant’s pseudo-stem, designing
a rotor assembly which consisting of two disks on which six blunt blades are mounted, and
a shaft design to drive this rotor assembly and the pulley and powering system for the
machine. This paper specifies the new model of machine and its working operation.

5
COMPONENTS AND DESCRIPTION
The components that are used in the project BANANA LEAF CUTTER” are as
follows,
1. Shaft
2. Larger pulley
3. V-Belt drive
4. Bearing
5. Bolts & nuts
6. Pulley
7. Motor
8. Die
9. Circular disc
10.Quick return Mechanism

2.2.1 Shaft

A drive shaft, driveshaft, driving shaft, propeller shaft (prop shaft), or Cardan shaft
is a mechanical component as shown in fig 2.1 for transmitting torque and rotation,
usually used to connect other components of a drive train that cannot be connected directly
because of distance or the need to allow for relative movement between them.

Figure : 2.1 Shaft

6
2.2.2Larger pulley

A larger pulley is a rotating mechanical device that is used to store rotational energy
Providing continuous energy when the energy source is discontinuous. As shown in fig 2.2
For example, flywheels are used in reciprocating engines because the energy source,
torque from the engine, is intermittent.

Figure: 2.2larger pulley

2.2.3 V-Belt Drive:

Connecting the V-belt pulleys, it transmits the force from the engine to the ancillary
components including the alternator, the hydraulic pump for the power steering, the air
conditioning compressor, the fan and the water pump. As shown in fig 2.3 In a
combustion engine, the combustion of the air/fuel mixture drives pistons.

Fig: 2.3V-belt drive

7
2.2.4 Bearing:

A pillow block is a pedestal used to provide support for a rotating shaft with the
help of compatible bearings & various accessories. Housing material for a pillow block is
typically made of cast iron or cast steel. As shown in fig 2.4

Fig: 2.4 Bearing

2.2.5 Bolts & Nuts

The purpose of inserting bolts into other materials is to bind that material with
another object. As shown in fig 2.5. The nut is always used opposite a mating bolt and
features a threaded hole which mates with the thread on the bolt. When used together, nuts
and bolts work to fasten a stack of parts together securely.

fig: 2.5 Nut and bolt

8
2.2.6 Pulley

A pulley is a wheel on an axle or shaft that is designed to support movement and change
of direction of a taut cable or belt along its circumference. As shown in fig 2.6. Pulleys are
used in a variety of ways to lift loads, apply forces, and to transmit power.

Fig :2.6 pulley

2.2.7 Motor

An electric motor is an electrical machine that converts electrical energy into

mechanical energy. As shown in fig 2.7. The reverse of this is the conversion of
mechanical energy into electrical energy and is done by an electric generator, which has
much in common with a motor.

Fig :2.7 Motor

9
Specifications:

Motor Capacity : 0.5HP

Power Source : Electrical
Motor Pulley Size : 75mm
Electric Motor : 1440 Rpm

2.2.8 DIE

Fig :2.8 Die

A die is a specialized tool used in manufacturing industries to cut or shape material

mostly using a press. Like moulds, dies are generally customized to the item they are used
to create. Products made with dies range from simple paper clips to complex pieces used
in advanced technology.

10
2.2.9 CIRCULAR DISC

Fig :2.9 Disc

A disc is the region in a plane bounded by a circle. A disk is said to be closed if it

contains the circle that constitutes its boundary, and open if it does not.

2.2.10.QUICK RETURN MECHANSIM

Fig :2.10 Quick return mechanism

A quick return mechanism is an apparatus that converts circular motionrotating motion

following a circular path into reciprocating motionrepetitive back-and-forth linear motion
in presses and shaping machines, which are utilized to shape stocks of metal into flat
surfaces, throughout mechanical engineering. The quick return mechanism is the
foundation behind the energy of these machines.

The mechanism consists of an arm attached to a rotating disc that moves at a controlled
uniform speed. Unlike the crank, the arm of the mechanism runs at a different rate than the
disc. By having the disc run at a different rate than the attached arm, productivity increases
because the amount of time needed for a cut is reduced. The design of this mechanism
specializes in vector calculus and the physical aspects of kinematicsstudy of motion .

11
2.3 MACHINING PROCESS

2.3.1 CUTTING OPERATIONS:

Cutting is a collection of process where in is brought to a specified geometry by

removing excess material using various kinds of tooling to leave a finishing pat that meet
section.the net result of cutting is two products, the waste or excess material,and the
finished part.

2.3.2 TURNING:

Turning is machining process in which a cutting tool, typically a non-rotary bit,

describes a helical tool bath by moving more or less linearly while the workpiece rortates.
The tool’s axis of movement may be along some set of curves or angles , but they are
essentially linear in the nonmathematical. Usually the term ‘turning’ is reversed for the
generation of external surface by this cutting action where as the same essential cutting
action.When applied to internal surfaces that is holes of one kind of another is called
‘boring thus the pharse turning and boring catagories the larger family of essentially
similar process. The cutting of face on the workpiece that is, surfaces perpendicular to its
rotating axis,whether with a turning or boring tool, is called ‘facing’,and may be lumped
into either category as a subset.

Turning can be done manually, in a traditional form of lathe, which frequently requires
continuous supervision by the operation , or by using and automated lathe which does not.

Today the most common type of such automation is computer numerical control, better
known as CNC. CNC is also commonly used with many other types of machining besides
turning.

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2.3.3 FACING:

Facing is the process of removing metal from the end of the workpiece to produce a
flat surface. Most often , the workpiece is cylindrical , but using four jaw chuck you can
face rectangular or add shaped work to form cubes and other non-cylindrical
shapes.When a lathe tool removes metal it applies considerable tangential i.e.lateral or
sideways force to the workpiece. To safely perform a facing operation the end of the
workpiece must be positioned close to the jaws of the chuck.the workpiece should not
extend than 2-3 times its diameter from the chuck jaws unless a steady rest is used to
support the free end.

2.3.4 WELDING:

Welding is a process for joining similar metals. Welding joins metals by melting
and fusing 1, the base metals being joined and 2, the filler metal applied. Welding employs
pinpointed, localized heat input. Most welding involves ferrous-based metals such as steel
and stainless steel. weld joints are usually stronger than or as strong as the base metals
being joined.Welding is used for making permanent joints. It is used in the manufacture of
automobile bodies, aircraft frames, railway wagons, machine frames, structural works,
tanks, furniture, boilers, general repair work and ship building.

13
2.3.5 DRILLING:

Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular
cross section in solid materials. The drill bit is a rotary cutting tool often multipoint. The
bit is pressed against the work piece and rotated at rates from hundreds to thousands of
revolutions per minute. This forces the cutting edge against the workpiece, cutting off
chips from the hole as it is drilled.

Exceptionally, specially-shaped bits can cut holes of non –circular cross-section as

square cross section is possible .drilled holes are characterized by their shape edge on the
entrance side and the presence of burrs on the exit side unless they have been removed.

Drilling may affect the mechanical properties of the work piece by creating low
residual stresses around the holes opening and a very thin layer of highly stresses and
disturbed material on the newly formed surface .this causes the work piece to become
more susceptible to corrosion and crack propagation at the stresses surface. A finish
operation may be done to avoid these detrimental conditions.

For fluted drill bits,any chips are removed via the flutes. Chips may form long
spirals undesirable or small flakes,depending on the material, and process parameters. The
types of chips formed can be indicator of the machinability of the material, with long chips
suggesting poor material machinability.

14
 CHAPTER 3

DESIGN CALCULATIONS

3.1 FORMULA USED:

Power

Diameter of shaft

Diameter of smaller pulley

Dp = 1.5d

Force acting on pulley

T=FxR

Belt tension

Torque acting on larger pulley

T = (T1- T2 ) R

Cutting force

T=FxR

3.2 Cutting Force of the blade

T=FxR Torque (T) in N.mm
F = 1.25 N Radius of larger pulley (R) in mm
3.3 Torque acting on larger pulley
T=FxR
= 1.25 x 230
T = 262.5 N.mm
15
 Force acting on the smaller pulley
T=FxR Force (F) in N

F=

= F = 10 N

Belt tension

T1 = T2

T1 = 10.05 N
Diameter of shaft

T=

T = . 40. d ³

d³ =

d = 35 mm
Diameter of smaller pulley
Dp = 1.5d
Dp = 1.5(35)
Dp= 52.5 mm
Diameter of larger pulley
D = 8. Dp

16
 D = 8 (52.5)
D = 460 mm
3.4 POWER

Power P =

P =1.50KW
3.5. DESIGN CALCULATIONS FOR BELT

3.5.1SELECTION OF CROSS-SECTION (PSG DB P.NO: 7.58)

Power, P= 1.50 Kw and big pulley diameter, D=460mm, small pulley diameter, d=75mm
according to this value to select the cross-section symbol A.

3.5.2 DESIGN POWER

(PSG DB P.NO: 7.69)

Design power = Given power Service factor (Fa)

Length correction factor (Fc) arc of contact (Fd)
Corresponding heavy duty application of AC motor with high torque and 16hrs/day,
the service factor, Fa=1.5 (PSG DB P.NO: 7.53)

3.5.3 Length of belt for open belt drive

Speed reduction (i)

where, 6.14 = N= 156 rpm

17
corresponding speed ratio, i=6.14 and ratio =1.1

C = 1.1×D » C =1.1×460» C =506 mm

L = 1925.6 mm (PSG DB P.NO: 7.58)

correction factor, Fc=0.82

3.5.5 Arc of contact angle = 180 ̊ 60 ̊

= 180 ̊ 60 ̊

= 134.43 ̊

therefore smaller pulley angle is 135 ̊

For correction factor V-V is

Fd = 0.93

Design power, Pd =

pd= 1.50 Kw

BELT SPEED

V or S = =

V = 3.75 m/s

18
speed ratio , i = = = 6.14

Corresponding value of table, Fb = 1.13

Equivalent pitch diameter, de = dp × fb

= 75 × 1.13

de = 85 mm (PSG DB P.NO: 7.62)

For corresponding transmitting capacities,

Belt cross-section is A

KW =

Kw = 0.8205 kw

3.5.5 BELT RATING:

Belt rating for 132.63 = arc of contact = × 135

Belt rating = 0.615 Kw (PSG DB P.NO: 7.70)

3.5.6 CHANGE IN CENTRE DISTANCE (PSG DB P.NO: 7.61)

C=A+

A=

A =

A = 271.30 mm

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B=

B =

B = 800 mm

C = 271.35

C = 540 mm

3.5.7 INITIAL TENSION (PSG DB P.NO: 7.61)

L = 1925.6

L = 1916 mm

2D LAYOUTS OF MODEL

20
 WORKING PRINCIPLE

When the manual effort is applied to machine by rotating hand lever, it tends to rotate the
crank plate. Once the crank plate starts to rotate about its axis which causes the slotted link
gets coupled with it to take an angular motion. This angular motion is converted into linear
motion by ram with the help of coupler which couples ram and slotted link together. The
experienced translation of tool over the die creates a compressive force on its surface,
which tends to cut the leaf loaded on the surface of die. This method is repeated for
performing continuous cutting operation in an effective manner

21
 CHAPTER 4

FABRICATION DETAILS

4.1 MATERIAL SELECTION

Cast iron and mild steel was selected for this project due to its malleable property.
4.2 PROPERTIES OF MILD STEEL
Table 4.1 properties of mild steel
PROPERTIES MILD STEEL

Carbon content 0.15% - 0.45 %

Tensile strength 400MPa

Density 7850 kg/m

Young’s modulus 210GPa

Hardness 137

4.2.1 MACHINABILITY
It is the property of a material which refers to a relative case with which a material
can be cut.the machinability of a material can be measured in a number of ways such as
comparing the tool life a for cutting different material or thrust required to remove a unit
volume of the material.
4.2.2 HARDNESS
It is a very important property of the metal and has wide variety of meanings. the
hardness is usually expressed in number which are dependent on the method of making the
test.

22
4.3 MACHINING PROCESS
4.3.1 METAL CUTTING
The cutting operation is done on the metal cutting machine.cutting is performed on
to a specified geometry by removing excess material by using tool to leave a finishing part
.the metal can be obtained according to the required length after cutting the raw material.

Fig 4.1 metal cutting machine

Cold saws are saws that make use of a circular saw blade to cut through various types of
metal, including sheet metal. The name of the saw has to do with the action that takes
place during the cutting process, which manages to keep both the metal and the blade from
becoming too hot. A cold saw is powered with electricity and is usually a stationary type
of saw machine rather than a portable type of saw.
The circular saw blades used with a cold saw are often constructed of high speed
steel. Steel blades of this type are resistant to wear even under daily usage. The end result
is that it is possible to complete a number of cutting projects before there is a need to
replace the blade.High speed steel blades are especially useful when the saws are used for
cutting through thicker sections of metal.

23
 4.3.2 ARC WELDING

Welding is used for making permanent joints. It is used in the manufacture of

automobile bodies, aircraft frames, railway wagons, machine frames, structural works,
tanks, furniture, boilers, general repair work and ship building. Arc welding is a type of
welding that uses a welding power supply to create an electric arc between an electrode
and the base material to melts at the welding point. they can use either direct or alternating
current and consumable or non-consumable electrodes. the welding region is usually
protected by some type of shielding gas, vapour or slag. the base stand are welded
according to the required shape to cutting machine.

Fig.4.2 Arc welding

The operator needs to control the gap between the electrode tip and the work piece
while moving the electrode along the joint. In the shielded metal arc welding process
(SMAW) the 'stick' electrode is covered with an extruded coating of flux. The heat of the
arc melts the flux which generates a gaseous shield to keep air away from the molten pool
and also flux ingredients react with unwanted impurities such as surface oxides, creating a
slag which floats to the surface of the weld pool. This forms a crust which protects the
weld while it is cooling. When the weld is cold the slag is chipped off. The SMAW
process cannot be used on steel thinner than about 3mm and being a discontinuous process
it is only suitable for manual operation. It is very widely used in jobbing shops and for
onsite steel construction work.

24
4.3.3 DRILLNG

Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular
cross section in solid materials. The drill bit is a rotary cutting tool often multipoint. The
bit is pressed against the workpiece and rotated at rates from hundreds to thousands of
revolutions per minute. This forces the cutting edge against the workpiece, cutting off
chips from the hole as it is drilled. The drilling process has been used to drill the base,
larger pulley and blades.

Fig.4.3 drilling

4.3.4 BORING
In the boring process the holes are enlarged. The hole in the flywheel were bored to
get required shape for assembly process.

4.3.5 TURNING
Turning process has beeen used to reduce the diameter of the shaft.by this process
the shaft is made to the requried shape to use rotates the flywheel.

4.3.6 FACING
In order to remove the excessive material form the shaft we use process called
facing. This process helps to get good surface finidh on the shaft.

25
4.3.7 GRINDING

Grinding, an abrasive machining process that uses a grinding wheel as the cutting
tool, is capable of making precision cuts and producing very fine finishes. The grinding
head can be controlled to travel across a fixed workspace or work piece can be moved
while the grind head remains in a fixed position. the surface of the flywheel is removed
and get good surface because the blade is fixed at the flywheel.

Fig.4.4 grinding

4.3.8 SURFACE GRINDING

Surface grinding is an abrasive machining process in which the grinding wheel removes
material from the plain flat surfaces of the work pieceThe surface grinding process has been used
to sharp the blade edges and to remove the surface of the blade, to get good surface finish on the
blades.

Fig.4.5 surface grinding

26
4.3.9 ASSEMBLY
The fabrication components are shaft, flywheel , blade and motor were assembled
by fastening using nuts and bolts and also by using welding. Finally the fabrication parts
were assembled to get chaff cutter machine.
4.3.10 BILL OF MATERIALS

SL. NO. NAME OF THE PARTS MATERIAL QUANTITY

1 Motor - 1

2 Pulley Cast Iron 1

3 Bearing Stainless steel 4

4 Frame Mild steel 2

5 Shaft Mild Steel 1

6 V- Belt Drive - 1

7 Disc Mild Steel 1

8 Blades Mild Steel 1

9 Nuts And Bolts Mild Steel 10

10 Quick return Mechanism Mild Steel 1

27
4.4 ISOMETRIC VIEW OF MODEL

28
4.5 COST ESTIMATION

MATERIALS COST

SL. NO. NAME OF THE PARTS QUANTITY AMOUNT (RS)

1 Motor 1 1200

2 Pulley 1 650

3 Bearing 2 400

4 Disc 1 300

5 Shaft 1 300

6 V- Belt Drive 1 400

7 Frame As per 1000

required

8 Metal strip 1 300

9 Nuts And Bolts 16 150

10 Quick return mechnaisms 1 800

TOTAL= RS. 5500

29
LABOUR COST

Labour cost includes the following: LATHE, DRILLING, WELDING, GRINDING, POWER

HACKSAW, GAS CUTTING.

Cost = Rs.1000

The overhead charges are arrived by “Manufacturing cost”

Manufacturing Cost =Material Cost + Labour cost

= 5500+ 1000

= Rs.6500

4.6 ADVANTAGES AND APPLICATIONS

4.6.1ADVANTAGES
x The banana leaf is an alternative for plastic plates and also its is a decomposing
product.
x Cheaper and easily available material are used for construction of our system.
x Quick response is achieved.
x Simple in construction.
x Easy to maintain and repair.
x No fire hazard problem due to over loading.
x Comparatively the operation cost is less.
x Continuous operation is possible without stopping.
x It reduces the partial manual work.
x It reduces the production time.
x Occupies less floor space.

30
4.6.2 APPLICATION

This machines can be used in

x Hotels,
x Farmers who are planting plantain trees,
x Whole sellers who distribute banana leaves to the local resellers,
x Retail shop.

31
 CHAPTER 5

CONCLUSION AND REFERENCE

CONCLUSION
Leaf picking can be done using manual methods. But we have chosen automatic leaf
picking method because it reduces time consumption and human resources. Customer
satisfaction is good in automatic method and cleanliness is maintained in a perfect way.
Number of leaves collected will be higher in automatic method than in manual method.
Therefore the automatic leaf picking method is more preferable than manual methods.

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PHOTOGRAPH

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