COCONUT HUSK PEELER

Design project report: Group 13

Submitted by

NIBIN MATHEW - B18MEB49

NISHANTH J - B18BMEB50

MUHAMMED NAVLAJ - B18MEB51

PARTHAN S S - B18MEB52

The Kerala technological university

in partial fulfillment of the requirements for the award of the B Tech

degree in Mechanical Engineering

Department of Mechanical Engineering

T.K.M. College of Engineering, Kollam

2021 February
 DEPARTMENT OF MECHANICAL ENGINEERING
T.K.M COLLEGE OF ENGINEERING, KOLLAM

CERTIFICATE

Certified that this report entitled “COCONUT HUSK PEELER” is the report of design
presented by NIBIN MATHEW, NISHANTH J, MUHAMMED NAVLAJ AND
PARTHAN S S during 2020-21, in partial fulfillment of the requirements for the award of
the Degree of Bachelor of Technology in Mechanical Engineering of the A.P.J Abdul Kalam
Technological University of Kerala.

Prof. Leena R

Prof. Firoz N

Dr. Anand Sekhar R

Dept. of Mechanical Engineering

T.K.M. College of Engineering, Kollam

Dr. Mohammed Sajid N K

Head of the Department

Dept. of Mechanical Engineering

TKM College of Engineering, Kollam

 DECLARATION

We hereby declare that, this design project report entitled COCNUT HUSK PEELER is the
bona fide work of mine carried out under the supervision of Prof. Leena R, Dr. Anand
Sekhar R & Prof. Firoz.N. We declare that, to the best of our knowledge, the work reported
herein does not form part of any other project report or dissertation on the basis of which a
degree or award was conferred in an earlier occasion to any other candidate. The content of
this report is not being presented by any other student to this or any other university for the
award of a degree.

Nibin Mathew
Nishanth J
Muhammed Navlaj
Parthan S S

Prof. Leena R

Prof. Firoz N

Dr. Anand Sekhar R

Dr. Mohammed Sajid N K

Head, Dept. of Mechanical Engineering

TKM College of Engineering, Kollam Date: 01/02/2021

1
 ACKNOWLEDGEMENT

We take this opportunity to express our deep sense of gratitude and sincere thanks to all who
helped us to complete the project successfully.

We are deeply indebted to our guide Prof. Leena R, Prof. Firoz N & Dr. Anand Sekhar R
Department of Mechanical Engineering for their excellent guidance, positive criticism and
valuable comments. We are greatly thankful to Dr. Mohammed Sajid, head of Mechanical
Engineering Department for his support and cooperation.

Finally, we thank our parents and friends who directly and indirectly contributed to the
successful completion of our project.

Nibin Mathew
Nishanth J
Muhammed Navlaj
Parthan S S

Place: Kollam

Date: 01/02/2021
 ABSTRACT

Bic
 CONTENTS

Title Page no.

List of Figures 5
1. Introduction 6
2. Problem statements 7
3. Problem solutions 7
4. Methodology 8
5. Detailed design
5.1 Primary design 9
5.2 Final components used 11
5.3 Design aspect 12
5.4 Design calculation 13
5.5 Design model 15
5.6 Design analysis 16
6. Material manufacturing 18
7. Cost estimation 19
8. Conclusion 20
9. Reference 21
 LIST OF FIGURES

Figure Title Page

Fig 1 Initial Hand drawn design 9

Fig 2 Final CAD model 11

Fig 3 Isometric View 15

Fig 4 Gear, clutch and spring (dis-engaged) 15

Fig 5 Gear, clutch and spring (engaged) 15

Fig 6 Shaft to tyre gear arrangement 15
Fig 7 Engager and releaser levers 15
Fig 8 Shaft stress analysis 16
Fig 9 Shaft displacement analysis 16
Fig 10 Shaft strain analysis 16
Fig 11 Clutch stress analysis 16
Fig 12 Clutch strain analysis 16
Fig 13 Clutch displacement analysis 16
Fig 14 Ratchet and pawl stress analysis 17
Fig 15 Ratchet and pawl strain analysis 17
Fig 16 Ratchet and pawl displacement analysis 17
1. INTRODUCTION

In
1. PROBLEM STATEMENT

One of the most commonly used and ecofriendly mode of commuting is bicycles which
utilizes human power for drive. The main advantage we receive by the use of this mode of
commute is the conservation of energy and the added bonus of receiving exercise effect while
using these bicycles, hence people from various age groups use this mode to fulfill their need.
This is why finding a way to conserve even more energy from a system which is
comparatively highly sustainable to make it even more efficient.

The main unused potential source of energy found in these bicycles was:

The method used to slow down these bicycles still use a conventional technique
which uses frictional effect which convert kinetic energy into heat using brake
pads or disc brake system. This method wastes lot of unused energy in the form of
heat.

3. PROBLEM SOLUTION

We tried to tap into and utilize the hidden source of energy lost during the brake phase. The
method we tried to implement was with the help of spring and gear mechanism by storing the
kinetic energy into elastic energy in spring and later when required this energy can be used
for providing drive using gear and clutch mechanism.

The perks of having this system:

1. During deceleration phase less amount braking force is required for slowing down
the bicycle which helps to save braking pad material as well as to reduce wasting of
energy.
2. Because of the presence of the stored elastic energy in the spring the rider can use
the same during initial acceleration stage or during a more tedious driving situation
where more human energy is required like a slope.
 4. METHODOLOGY

Material
Problem
selection,analysis Cost estimation
Identification
and iteration

Brainstorming CAD model

session designing

Primary design
Fixing the idea
generation
 5. DETAILED DESIGN

5.1 PRIMARY DESIGN

• Gears
• Square jaw clutch
• Ratchet mechanism
• Spring
• Shaft
• Bearings
• Frame material

Fig 1 – Our initial hand drawn design

5.2 FINAL COMPONENTS USED
SL.NO COMPONENT DIMENSION MATERIAL WEIGHT
NAME USED
1 Engager and Length – 1060 Al Alloy 41 g
Releaser 129mm
2 Wire (2 Nos) Dia – 3mm, 1060 Al Alloy 14.5 x 2 g
Length –
700mm
3 Spring Outer Dia – Stainless 316 2054 g
90mm, Wire ASTM A316
Dia-10mm,
No. of active
coils – 14, Free
length 300mm
4 [INPUT] Tyre to 1) Dia-110mm, AISI 1023 1) 273.7
Shaft Gears ( 4 No. of teeth – g/piece
Nos) 10 (3 Nos) 2) 987g
2) Dia –
220mm, No. of
teeth – 20 (1
No.)
5 Rachet gear Dia – 170mm, AISI 4130 405.3 g
No. of teeth –
20
6 [OUTPUT] 1) Dia – AISI 1023 1) 307.1 g
Shaft to Tyre 110mm, No. of 2) 586.4 g
Gears teeth – 10. (1
No.)
2) Dia –
165mm, No. of
teeth – 15. (1
No.)
7 Clutch case Length – AISI 1023 249.56 g
36mm
8 Clutch Engager Length – AISI 1023 302.4 g
bearing 143mm
9 Clutch ( 2 Nos.) Dia – 50mm Al 7075 T6 100 x 2 g
10 Pawl Length – AISI 4130 52 g
60mm,
Thickness –
8mm
11 Shaft Length – AISI 1023 602 g
96.96mm,
Dia – 25.4mm.
Fig 2 – Final CAD model of the full system in Solidworks
5.3 Design aspects

1. Design for ergonomics-

• The system is made in such a way as to accommodate all the components onto the
mainframe of the chassis of the bicycle without creating any hindrance to rider comfort
• The system operation is made as simple as possible by the use of a switch mechanism
which helps the rider to maintain his/her focus towards the road
2. Design for safety-
• The overall system is enclosed in secure casing which prevents any sort of accidents that
can happen to the rider
• Factor of safety is ensured to be high enough so that any unintended failures won’t
occur
3. Design for manufacturability
• The overall product is designed in modular fashion so that the production of individual
components can be done which helps to decrease the production time and cost.
• The components having complex designs are being made with raw materials which can
be manipulated easily to simplify the manufacturing process.
4. Design for sustainability
• Most of the raw materials are reusable or recyclable materials which helps prevent
environment pollution
The overall product life is ensured to be high due to less chance for components to fail
and due to the use of pure mechanical components
5. Design for convenience
• The bicycle drive system helps the rider during the initial acceleration stage after
braking.
• Because of the modular design of the product, it helps the user to conveniently transfer
the system from one bicycle to another with ease.
6. Design for cost
• Materials are selected after proper stress tests so that wherever the stress values are low
cheaper materials are used to save cost
• The overall product is made in modular design which helps to manufacture the same
easily and more efficiently enabling us to save manufacturing cost
5.4 Design Calculation
5.5 Design model
Fig 3 – Isometric view Fig 4 – Gear, clutch and spring
assembly(clutch disengaged)

Fig 5 – Gear, clutch and spring assembly (clutch- Fig 6 – Shaft to tyre gears
Engaged)

Fig 7 – Engager and releaser levers

5.6 Design Analysis

Fig 8 –Shaft Stress Analysis Fig 9 – Shaft displacement analysis

Fig 10 –Shaft Strain Analysis Fig 11 – Clutch Stress Analysis

Fig 12 – Clutch Strain Analysis Fig 13 – Clutch Displacement Analysis

 Fig 14 – Ratchet gear and pawl Stress Analysis

Fig 15 – Ratchet gear and pawl Strain Analysis

Fig 16 – Ratchet gear and pawl displacement analysis

 6. MATERIAL AND MANUFACTURING

1. Given below is a table showing the properties of each material that we considered to
use.
2. The material for each part is taken by considering the amount of force that acts on it, its
stress analysis is done and the one which has high FOS combined with low cost is
taken.
3. Machinability of the material is another thing we have considered for material
selection, some components are hard to machine due to its complex shape. For these
parts we use materials having high machinability.
4. The reason for not using the Hexcel carbon fiber is due to its high cost compared to the
alternatives and this prevents our aim to produce a cheap affordable product.

MECHANICAL 1023 Carbon AISI 4130 ALUMINIUM 7075-T6 HEXCEL CARBON

PROPERTIES Steel FIBRE
DENSITY 7.858 g/cm3 7.85 g/cm3 2.81 g/cm3 1.78 g/cm3
TENSILE 425 MPa 670 MPa 572 MPa 4480 MPa
STRENGTH
YIELD STRENGTH 360 MPa 435 MPa 503 MPa 2206 MPa
SHEAR MODULUS 80 GPa 80 GPa 26.9 GPa 5.61 GPa
BULK MODULUS 140 GPa 140 GPa 71.7 GPa 15.8 GPa
ELASTIC MODULUS 190-210 GPa 205 GPa 71.7 GPa 75 GPa

POISSON’S RATIO 0.27 - 0.30 0.29 0.33 0.335

HARDNESS 121 197 150 57.64
BRINELL
ELONGATION AT 15% 25.5% 11% 1.8%
BREAK
MACHINABILITY 65 70 70 60
 7.COST ESTIMATION

1. For cost estimation first we found out the prices of the material used per kg .
2. Then the amount of each material required and their corresponding price is calculated
from the weight of the components.
3. Machining cost for 1 hour in a CNC machine is known, with that the total machining
cost of the components is calculated.
4. Adding all these we get the total estimate cost for one product.

Raw material cost (per kg) -

1060 Al alloy- ₹250
Spring- ₹1000
AISI 1023- ₹50
AISI 4130- ₹150
Al 7075 T6- ₹600
Total raw material cost for one product- ₹1398.8
Machining cost- ₹400 per hour for CNC machining
Total machining cost for one product- ₹600
Total estimate for one product- ₹1998.8
 CONCLUSION

In this current era people are trying to conserve energy and find alternative sustainable
sources and our products fits into this category as best as a product can be. Our product
helps to reduce human effort through ones everyday commute while ensuring the concept
of sustainability and optimise the use of energy as much as possible with the tools and raw
materials we have at our disposal in this present era.
Our product ensures the concept of sustainability, manufacturability, ergonomics, safety
without having to compromise on increasing cost.
.
 REFERENCE

1. Material Properties - http://asm.matweb.com/

2. Spring Selection and optimisation - https://www.acxesspring.com/compression-

spring-calculations.html

3. Software used –

4. Ratchet and pawl mechanism - https://education.lego.com/en-

us/lessons/advancing-with-spm/pawl-and-ratchet#connect
5. Design of Machine Elements by V B Bhandari