DESIGN AND FABRICATION OF

INNOVATIVE MULTI-ROTOR
ROTOTILLER
Table of Contents
1. INTRODUCTION .................................................................................................. 7
1.1 Types, Parameters and Problems of Rotary Tillers .......................................... 7
1.1.1 Tractor-Rotavator ....................................................................................... 7
1.1.2 Power Weeder ............................................................................................ 8
1.1.3 Rototiller..................................................................................................... 8
1.1.4 Soil Parameters ........................................................................................... 9
1.1.5 Tillage Parameters .................................................................................... 11
1.1.6 Rotary Tiller Kinematics .......................................................................... 17
1.1.7 General Associated Problems .................................................................. 20
1.2 Proposed Solution ........................................................................................... 20
1.2.1 Scope of the Project ................................................................................. 21
1.2.2 Proposed General Model .......................................................................... 21
2 MATHEMATICAL DESIGN .............................................................................. 23
2.1 General Description, Basic Specifications and Constraints............................ 23
2.1.1 Engine Power ........................................................................................... 23
2.1.2 Forward Speed.......................................................................................... 23
2.1.3 Working Width (b) ................................................................................... 23
2.1.4 Number of Flanges & Blades ................................................................... 24
2.1.5 Working Depth ......................................................................................... 25
2.1.6 Bite Length ............................................................................................... 25
2.2 Work Calculation ............................................................................................ 25
2.2.1 Specific Work ........................................................................................... 25
2.2.2 Performable Work .................................................................................... 27
2.3 Design of Rotavator Elements ........................................................................ 28
2.3.1 Design of First Rotor Parameters ............................................................. 28
2.3.2 Design of Second Rotor ........................................................................... 31
2.3.3 Plotting the Cutting Trajectory of the Tiller Blade .................................. 35
2.3.4 Gross Concept Error Alternate Provisions ............................................... 36
2.4 Determination of Transmission Ratio ............................................................. 36
3 MODELING AND FABRICATION ................................................................... 38
 3.1 CAD Modeling and Preparation ..................................................................... 38
3.2 Purchase of Components................................................................................. 39
3.3 Laser Cut and Lathe Operation ....................................................................... 40
3.4 Assembly and Welding ................................................................................... 40
References .................................................................................................................... 40
INDEX OF FIGURES
Figure 1 Tractor Rotavator ............................................................................................. 8
Figure 2 An L-Blade ..................................................................................................... 13
Figure 3 Rotavator mounted with J-blades ................... Error! Bookmark not defined.
Figure 4 A C-Blade....................................................................................................... 14
Figure 5 Blade Parameters ............................................................................................ 14
Figure 6 Blade Forces ................................................................................................... 15
Figure 7 Direction of Rotation ..................................................................................... 16
Figure 8 Cutting Trajectory with two blades mounted to a side of the flange ............. 17
Figure 9 Shape of Soil Slice for Up and Down-cut Actions ........................................ 18
Figure 10 General Proposed Model .............................................................................. 22
Figure 11 Multi-rotor Arrangement.............................................................................. 24
Figure 12 Specific Work Calculation ........................................................................... 26
Figure 13 Performable Work in positive range ............................................................ 27
Figure 14 Optimized Parameters .................................................................................. 29
Figure 15 Calculation of Pushing Velocity .................................................................. 31
Figure 16 Chart of Second Rotor Parameters ............................................................... 34
Figure 17 Cutting Trajectory plotted ............................................................................ 36
Figure 18 Sprockets purchased ..................................................................................... 39
Figure 19 Gearwheels purchased .................................................................................. 39
INDEX OF EQUATIONS
Equation 1-1 Frictional Stress in blade span ................................................................ 10
Equation 1-2 Angle of Incidence of the blade .............................................................. 10
Equation 1-3 Normal Stress in the blade ...................................................................... 10
Equation 1-4 Kinematic parameter lambda .................................................................. 11
Equation 1-5 Tangential Blade Speed .......................................................................... 12
Equation 1-6 Tangential Force ..................................................................................... 15
Equation 1-7 Equation of Cutting Trajectory ............................................................... 17
Equation 1-8 Bite Length ............................................................................................. 19
Equation 1-9 PTO Power .............................................................................................. 19
Equation 1-10 Tiller Force ........................................................................................... 19
Equation 1-11 Cutting Power ....................................................................................... 20
Equation 1-12 Frictional Power .................................................................................... 20
Equation 2-1 Angular displacement between blades ................................................... 24
Equation 2-2 Specific Work ......................................................................................... 25
Equation 2-3 Performable Work .................................................................................. 27
Equation 2-4 Rotor RPM .............................................................................................. 28
Equation 2-5 Pushing Power ........................................................................................ 30
Equation 2-6 Pushing Velocity ..................................................................................... 30
Equation 2-7 Target Influence forward speed .............................................................. 32
Equation 2-8 Pushing Velocity of second rotor ........................................................... 33
Equation 2-9 Second rotor radius ................................................................................. 33
Equation 2-10 time interval .......................................................................................... 35
INDEX OF TABLES

Table 1-1 Soil Type and Specific Soil Resistance........................................................ 11

Table 1-2 Soil Types and Blade Life ............................................................................ 15
Table 2-1 Blade Parameters .......................................................................................... 25
Table 2-2 Variable Inter-Dependencies........................................................................ 28
Table 2-3 Time Intervals at angles through single rotation .......................................... 35
 1. INTRODUCTION
A Rotavator (derived from rotary cultivator) or Rotary Tiller is an active tillage
implement that expends energy through blades mounted on flanges driven by tractor
PTO directly upon the soil to obtain desirable soil structure, prepare seedbed for
cultivation and remove weeds. It does so by processing the soil with rotary action in a
different speed from the tractor forward speed. The added advantage is that the
pulverizing action of blades results in good clod size distribution. The actual depth of
tillage for each blade changes throughout the rotational path of the cutting blade (2).
Compared to passive tillage implements like plough, Rotavators have high specific
energy requirements but the total power consumed per unit area of land is
significantly lower. This is due to the combination of multiple operations like primary
and secondary tillage done by passive tools into one (1). Primary tillage results in
preparing suitable seed bed and destroy weeds grown on the surface and improve soil
physical condition followed by secondary tillage which improves soil pulverization,
conserves moisture and cut chops the crop residue and mixes vegetative matter with
top soil. A Rotavator has a useful life of 8 years with 300 annual hours within which
the blades need to be replaced periodically at every 80-200 hours. Five lakh blades are
estimated to be annually required by the market (3).

1.1 Types, Parameters and Problems of Rotary Tillers

Based on mode, type of field used in and purpose, we are broadly classifying
Rotavators into three types: Tractor-Rotavator, Power Weeder and Rototiller. Apart
from this, they can also be classified upon number and direction of rotors but there are
not much commercially available variants of machines/implements containing
multiple rotors. This project attempts to create a multi-rotor Rototiller.

1.1.1 Tractor-Rotavator
A Tractor-Rotavator is the one mounted to the back of a tractor and is driven in fields.
Their working widths usually vary between 1.20 to 1.8m for tractors of 45HP and
higher power (3). The mounting arrangement is usually a three point hitch which is
used to adjust working depth of the implement hydraulically during operation. This is
essential to avoid the implement from operating rocks and other unwanted things in
the field (4). Some Tractor-Rotavators come equipped with multi-speed gearboxes
which facilitate changing PTO reduction ratios within two limits.
 Figure 1 Tractor Rotavator

1.1.2 Power Weeder

Power Weeders are also called Hand Tractors or Walking Tractors. They are used in
smaller fields and gardens where there is crop plantation in rows. Power Weeders are
commonly used to remove weeds and provide ventilation to the soil. Another marked
feature is that these implements have powered wheels that steer them at the desired
forward speed. Since a human has to physically walk with the machine, the forward
speed is limited to the range of 1 to 2.5 kmph. In both Tractor-Rotavator and Power
Weeder, blades contribute forward or negative thrust depending upon the direction of
rotation with respect to vehicle forward motion (2). We will get to see about this
concept in section 1.1.5.3.

1.1.3 Rototiller
A Rototiller is agricultural equipment that differs from a Power Weeder in the aspect
that there are no driving wheels present. The rotor, along with its blades, takes up both
the functions of tillage and pushing the vehicle forward. These types of Rotavators are
most suited for small scale farms and gardening. The advantages are obvious that
include cheap construction and smaller dimensions due to elimination of the need for
separate powertrain for wheels.

1.1.3.1 Human Fatigue

The most significant disadvantage of Rototiller lies is the fatigue load inflicted upon
the operator. With rotor carrying both the tillage and driving functionalities, the
implement moves forward or sidewise abruptly whenever it encounters hard surface or
materials. Also, the implement constantly moves up and down in short cycles during
operation due to difference in soil compaction as it moves forward. This makes it
difficult for the operator to work with it continuously for longer time.

1.1.3.2 Pushing Velocity

Since there are no driving wheels in the Rototiller, the forward velocity of the
implement is the result of horizontal component of the Tiller Force1 exerted by the
blades and is entirely set on the basis of prior experience alone. So, there is this need
for analytically determining the pushing velocity of the rotor in order to determine
Bite Length 2 of the machine with certainty. There is currently no literature in
academia dedicated to calculation of kinematics of Rototiller. We are attempting to fill
that void by designing a Rototiller that has its forward velocity in our control.

1.1.3.3 Depth Skid and Control

A commercially available Rototiller in the present is fitted with what is called the
Depth Skid. It is essentially a vertical channel mounted to the back of the vehicle
chassis that skids in the soil. It has a sharper bottom plate that provides negative tip
reaction to the direction of vehicle motion. The Depth Skid has an added functionality
of maintaining the operating depth of the Rototiller which is achieved by adjusting the
channel up and down through a series of mounting holes.

1.1.4 Soil Parameters

The soil’s physical, mechanical and dynamic properties greatly influence energy
requirements of the tillage equipments. This is because these soil parameters affect
soil strength which the tillage tool needs to overcome (2).

1.1.4.1 Soil Physical Properties

Some of the important physical properties that affect strength of the soil are:

• Moisture Content
• Bulk Density
• Soil Texture

Moisture content is expressed with respect to water content of dry materials. Moisture
content is also known to affect bulk density of the soil which, in turn, affects soil-
metal friction properties3. Bulk density of a soil is a function of soil water content at
any given amount of compactive effort. Soil Texture can be defined as the presence or
absence of water in void spaces of the soil. Soils at same mechanical and
environmental conditions, but different textures, behave differently.

1
This shall be explained in 1.1.6.3
2
This shall be explained in 1.1.6.2
3
This shall be explained in 1.1.4.2
1.1.4.2 Soil-Metal Friction
Soil failure, apart from taking place at shear mode, also occurs in the boundary
between tillage tool and soil. Hence, the force of friction between the materials needs
to be overcome. Among numerous relationships found by investigators for this force,
equation 1-1 appears to be capable of accounting for the complexities and
inconsistencies associated with the agricultural soils (2).
Equation 1-1 Frictional Stress in blade span

𝜏𝑓 = 𝐶𝑎 + 𝜎𝑛 tan 𝛿
Equation 1-2 Angle of Incidence of the blade

(𝑅 − 𝑎)
𝛿 = tan−1 ( )
𝑅
Equation 1-3 Normal Stress in the blade

𝐹𝑇
𝜎𝑛 =
𝐴𝑛

Where:

𝐶𝑎 = adhesion stress between the soil and the tillage tool (kPa)

𝛿 = angle of soil‐metal friction (degrees)

𝜎𝑛 = normal stress (kPa)

𝜏𝑓 = maximum frictional stress at the soil‐tool interface (kPa)

𝑅=rotor radius (m), 𝑎=working depth (m), 𝐹𝑇 =Tiller Force (N), 𝐴𝑛 =normal area (m2)

Soil-Metal friction is affected by numerous factors including soil water content, soil
porosity or density, sliding velocity. Soil density or porosity has an insignificant effect
on the coefficient of friction, but significantly affects the adhesion component of the
frictional shear stress. The value for adhesion stress between metal and soil has been
found experimentally as 7.933 kN/m2 at depth of 200 mm and 13.97 % soil water
content (2 pp. 130-132).

1.1.4.3 Soil Strength

Soil’s Strength is defined as its resistance against cutting tool and is measured in terms
of resistance force offered per unit area. The value of specific soil resistance is
depending upon the type of soil and moisture content. Table 1-1 gives values of
specific soil resistance for different types of soils (5).
 S. Type of Specific Soil Resistance Optimum Moisture Content
No Soil (Kg/cm2) (%)
1 Sandy Soil 0.21 3.5
Sandy
2 0.34 5.8
Loam
3 Clay 0.4-0.56 7.18
Heavy
4 0.5-0.7 13.3
Loam
Table 1-1 Soil Type and Specific Soil Resistance

1.1.4.4 Soil Structure

One of the primary motives of tilling the soil is to obtain desired soil structure. Soil
structure influences the following crop-growth parameters (3):

• Rainfall Retention
• Air Ventilation and Capacity
• Resistance to Root
• Rapid Infiltration

Granular soil structure is the most preferable one in the view of above-mentioned
parameters. It also influences energy requirements of the tillage process especially in
down-cut4 Rotavator action where the backside of the blades interfere with uncut soil
surface as the machine progresses forward. Water retention in wet paddy fields is
achieved by underwater rotary tillage (puddling 5 ) thereby mixing soil and water
completely so that the homogenous mixture is in suspension state during planting (2).
Puddling Quality is measured in terms of the following parameters:

• Pulverization Index
• Mixing Index
• Reduction in Bulk Density

1.1.5 Tillage Parameters

1.1.5.1 The Rotavator Kinematic Parameter, λ

The Kinematic Parameter λ is the ratio of blades’ peripheral velocity to the forward
speed of the machine. It is one of the most important operational parameters of the
Rotavator to quantify its performance as it affects both the tilth quality and energy
requirements (2).
Equation 1-4 Kinematic parameter lambda

𝑢
𝜆=
𝑣

4
This shall be explained in section 1.1.5.3
5
Puddling is sometimes referred to as churning.
 Equation 1-5 Tangential Blade Speed

2𝜋𝑁𝑅
𝑢=
60
Where:

𝑢=tangential blade speed in m/s

𝑣=forward speed of the set in m/s

𝑁=rotor rpm

𝑅=rotor radius in m

λ is a dimensionless parameter that can be altered by altering the following

parameters:

1. Rotor radius
2. Rotor rpm
3. Machine Forward Speed

For a given machine, only the second and third parameters can be changed as the rotor
radius, decided usually by radius of the flange, is fixed. After comprehensively
reviewing research literature of past studies on the effect of λ on the specific energy or
power requirements, Hendricks and Gill (1971c) made the following general
conclusions (2):

• Decreasing λ by increasing forward travel speed, results in an increase in the

power requirement, but a reduction in the specific power (provided the
geometry of the soil‐tool system is not significantly varied).
• Decreasing λ by decreasing angular velocity of the rotor, decreases the power
requirement and the specific power.
• Increasing λ results in a greater value of the ratio between cutting area and the
volume of the soil slice cut.

1.1.5.2 Blade Types

There are three types of blade profiles commercially available in the Indian market: L,
C, J-shaped blades. Each type of blade is used for different purposes and also for
different soil conditions. L-blades do not have curvature in both front and side views
whereas C-blades are curved in both front and side planes. J-blades are also called C-
L Hybrids (2) as they have curvature in front plane but not in side plane. Other types
of blades include hook‐shaped or pick‐type blades and the hoe‐type ones (2).

Following are the different usage and characteristics of L, C and J-type blades:

• L-shaped blades are used for thrashing crop residue and remove weeds. They
are not relatively good in penetration and pulverization. J-blades are used for
loosening the soil and provide aeration to the sub-soil surface. (5) (6)
• L-blades have flatter bottom span that slides over the soil surface just below

Figure 2 An L-Blade

the operating depth. Prolonged usage of L-blades results in the formation of

compacted sub-soil layer which would hinder root penetration. (3)
• C-shaped blades have greater curvature and therefore are recommended for
penetration in hard fields. Excessive loads in other blades cause tip wear.
• L-blades have the greatest forward thrust influence among all the blade types
while C-blades has the least influence and consume 30% (or 19% as contended
by some investigators) lesser PTO power than L-blades (2).

All three types of blade profiles can be defined with the following parameters:

1. Blade span, w
2. Effective vertical length, Lv
3. Blade cutting width, Lh
4. Radius of curvature between vertical and horizontal faces, R
5. Blade angle, 𝜃
 Figure 4 Blade Parameters

6. Clearance angle, 𝛽

Figure 3 A C-Blade

7. Blade thickness, t

The combination of blade parameters can be optimized for minimizing wear and
lowering power required (3) (5) (1). Both L and C-blades can be used in tandem in the
same Rotavator whereas J-blades require different rotor flange arrangement as they
can be mounted in more number of flanges due to lesser cutting width. Bolt diameter
of 10mm and 12mm has been suggested by Japanese investigators at Mie University.
Following table 1-2 gives life of different blades in general (3):

S. No Soil Type Life in hours

1 Laterite 40-50

2 Red 50-60

3 Terai 50-300

4 Sandy 150-200
Table 1-2 Soil Types and Blade Life

There are two major forces that need to be accounted for while designing rotary tiller
blades: Tangential Force and Soil Force which acts throughout in the cutting edge of
the blade and is a function of tangential force and number of blades in total. The
tangential force or tillage that acts on the tip of the blade is given (6) by:

Figure 5 Blade Forces

Equation 1-6 Tangential Force

71620𝑁𝑒 𝑃𝑒
𝑇=
𝑁𝑅
Where:

𝑁𝑒 =engine power in Ps, 𝑃𝑒 =transmission efficiency 80%

1.1.5.3 Direction of Rotation
Depending upon cutting direction with respect to vehicle forward motion, Rotavators
can be classified into up-cut and down-cut Rotavators. The shape of soil slice is
influenced by direction of rotation (4) but Bite Length is unaffected as it is a function
of blade speed and forward speed alone.

Both Power Weeder and Rototiller equipments have hitherto been constructed having
single down-cut rotor only. Tractor-Rotavators are equipped with two rotors
sometimes but they are not yet commercially available in large scale. As far as energy
and torque requirements are considered, up-cut Rotavators consume lesser energy
since the down-cut blades cut an increment of undisturbed soil, thereby consuming
20-30% higher torque, while up-cut blades operate an area already tilled by
predecessor blades after initial entry. Down-cut Rotavators exert forward thrust upon
the driveline which is, though detrimental in the longer run, helpful in limited traction
conditions. For this reason, down-cut Rotavators are widely employed in Paddy rice

Figure 6 Direction of Rotation

fields of the Asian subcontinent where it is usual to maintain the fields at wet
conditions before planting (2).
1.1.5.4 Depth and Width of Tillage
Depth of tillage, denoted by ‘a’, has a linear effect on total power requirements for
both up-cut and down-cut Rotavator actions but inversely affects specific energy
requirements and the degree of decrease is greatly affected by direction of rotation
(Shibusawa, 1993).

A commercial Power Weeder, for example, Mitsubishi VST SHAKTI 130DI has an
optimal working depth and width of 15 and 70 cm respectively (7). The rapid increase
of energy requirements with the increase in tillage depth is attributed to restricting the
Rotavator to be operated at shallow depths of tillage. The reason for this rapid
increase in energy demand had been solved in a study by Shibusawa (1993) in which
he claimed that there is a tremendous amount of re-tillage occurring in commercial
Rotavator blades and that it further increased significantly with increase in tillage
depth. (2)

Working width, in all cases has been found to increase specific work and hence
energy requirements. Working widths usually vary between 1.20 to 1.8m for tractors
of 45HP and higher power (3). Working width of Power Weeders and Rototiller are
limited by the type of field in which they are going to operate and the values of which
fall in the range of 450mm to 900mm.

1.1.6 Rotary Tiller Kinematics

1.1.6.1 Equation of Cutting Trajectory of the Tiller Blade

Figure 7 Cutting Trajectory with two blades mounted to

a side of the flange

The motion of the tip of the blade can be explained in two parts or components:
motion around the rotor axis and motion in horizontal direction. To put simply, the
cutting trajectory is essentially a cycloid with the circle slipping at a higher peripheral
speed than forward speed. Therefore the horizontal component of the curve has two
parts and the vertical component has one part.
Equation 1-7 Equation of Cutting Trajectory

𝑥 = 𝑣𝑡 + 𝑅 cos(𝜔𝑡 )
 𝑦 = 𝑅 sin(𝜔𝑡 )

Where:
‘t’ is time taken and ‘𝜔’ is angular velocity of the blades.

1.1.6.2 Length of Soil Slice Cut

Bite Length or Length of Soil Slice Cut is the distance between intersections at the
soil surface of two successive blades’ mounted to the same side of the flange as the
machine moves forward. The length is given by (2):

𝐿𝑏 = 𝑣𝑡𝑏

Where:

𝑡𝑏 =time through which blades rotate through the angle equal to the angle between
successive blades in the same side of the flange.

Figure 8 Shape of Soil Slice for Up and Down-cut Actions

The circumferential span is divided among certain number of blades. Therefore time
𝑡𝑏 is given by the following equation:
2𝜋
𝑡𝑏 =
𝑧𝜔
Where:

z=number of blades mounted to the same side of the flange,

𝜔=angular velocity in rad/s

Therefore the bite length is given as:
2𝜋
𝐿𝑏 = 𝑣
𝑧𝜔
Equation 1-8 Bite Length

2𝜋𝑅
𝐿𝑏 =
𝜆𝑧
Hence Bite Length can be controlled with the following factors:

1. Rotor radius
2. Rotor rpm
3. Forward speed
4. Number of blades mounted to one side of the flange

1.1.6.3 Forces Acting and Power Division

The torque-requirement sources which the engine power need to overcome are
identified (2) (6) as follows:

• Cutting the soil in shear

• Accelerating the cut soil
• Overcoming soil-soil friction
• Overcoming soil-metal friction
• Tip reaction to penetration

Engine BHP en route powertrain encounters efficiency losses and the final PTO
Power is calculated (4) accounting for unforeseen loads and other safety factors as
follows:
Equation 1-9 PTO Power

𝑃𝑇𝑂 𝑃𝑜𝑤𝑒𝑟 = 𝐸𝑛𝑔𝑖𝑛𝑒 𝐵𝐻𝑃 × 0.87 × 0.80

This power imparts Tiller Force (Ft) upon the soil and is calculated in usual Power-
Velocity relation as follows:
Equation 1-10 Tiller Force

𝑃𝑇𝑂 𝑃𝑜𝑤𝑒𝑟 × 60
𝐹𝑡 =
2𝜋𝑁𝑅
Cutting Force is defined as the product of specific soil strength and area of cross-
section of soil slice cut.

𝐹𝑐 = (𝑎 × 𝐿ℎ )𝐾0
Cutting Power:
Equation 1-11 Cutting Power

2𝜋𝑁𝑅
𝑃𝑐 = 𝐹𝑐 ( )
60
Frictional Force can be calculated (2) from the Frictional Stress as follows:

𝐹𝑓 = 𝜏𝑓 × 𝐴𝑛

Where, An is the normal area equal to product of blade span and cutting width.

Frictional Power:
Equation 1-12 Frictional Power

2𝜋𝑁𝑅
𝑃𝑓 = 𝐹𝑓 ( )
60
1.1.7 General Associated Problems
The limitations of current Rototiller equipments and Rotary Tillers in general are
listed collectively as follows:

1. Conventional single-rotor systems are not capable of operating in fields in

which the vegetation is highly fibrous and/or of high moisture content. The
rotor has to be periodically cleaned; else the operating depth becomes quite
low.
2. Conventional Rototiller equipments are highly un-reliable in terms of work
quality parameters like the Rotavator kinematic parameter𝜆, operating depth
and they cause high fatigue to the operator.
3. There are no dedicated academic attentions directed towards calculating work
parameters of Rototiller equipments which are more affordable than Power
Weeders.

1.2 Proposed Solution

Keeping in mind all the things we reviewed from literature and insights gained out of
experienced people, we conceived an idea for a new type of Rototiller that houses two
functional and counter-rotating rotors whose net influence on the forward speed of the
machine can be restrained within design limits. Rototiller is chosen in place of Power
Weeders since there is already enough academic literature dedicated to it and also
because Rototiller equipments are comparatively cheaper.

The addition of rotor offers us various design parameters to try out and arrive at an
optimum combination. Such parameters include:

• Center distance between the rotors

 • Relative rotor rotational speeds
• Individual directions of rotation
• Number of blades in each flange

1.2.1 Scope of the Project

The scope of this project is the design of following things in an agricultural Rototiller:

• Transmission System
• Body and Chassis Arrangement
• Multi-rotor System and Blades Arrangement
• Control System and Ergonomics

Following are things that make up the innovation part of the project:

• Multi-rotor System
• Blades Arrangement
• Pushing Influence Determination

1.2.1.1 Objectives
Our specific objects are as follows:

1. To develop an analytical model for determining pushing velocity of Rototiller

2. To develop an analytical model for determining parameters of the second rotor
of a Rototiller
3. To design a suitable transmission system for the developed multi-rotor model
on the basis of Specific Work Method (SWM)
4. To design and fabricate a suitable chassis frame and other sub-systems

1.2.2 Proposed General Model

To achieve the above-mentioned objectives a block diagram consisting of input
parameters and expected results during the process of tillage has been developed.
Since these is a completely new attempt and especially in the field of agricultural
machinery where there are so many unforeseen factors, it is obviously possible that we
might have missed out some crucial factors during design stages. It is for this reason
we incorporated some alternate provisions that completely contradicts design
calculations, which can be easily enforced into operation.
Control Parameters

Expected Outputs
Direction of Cut Bite Length
Number of Tillage Pushing
Process

Blades Influence and

& Velocity
Blade
Configuration Weed Eradication Operating
Rotational Depth
Speed Low Operator
Fatigue

Figure 9 General Proposed Model

 2 MATHEMATICAL DESIGN
Our Roto-tiller design mathematics starts with the calculation of specific work of the
machine at a range of forward speeds and lambda varied uniformly between the
possible upper and lower limits. We then calculate performable work of the machine
of given engine power at the same forward speeds and two working width values. For
this purpose, an excel spreadsheet has to be created and the lambda value at each
forward speed where the specific work is closest to the performable work is chosen so
that the engine power is utilized to the maximum.

2.1 General Description, Basic Specifications and Constraints

This section elaborates some set parameters, limitations in the machine and some
basic measurements which need to be complied with.

2.1.1 Engine Power

Engine power of commercially available Rototiller is usually limited to 6.5HP which
have base rpm of 2100. They come mounted with a 2-inch single B-groove pulley to
which we can connect our transmission system with belt. Engine bed need to have
adjustment provisions for movement in both longitudinal and transverse directions so
that it can accommodate extension due to belt-wear and to account for manufacturing
errors respectively. From experience gained out of previous attempts in designing and
fabricating power welders, we have learnt that the center distance between engine
pulley and the pulley to which the power is transmitted to have to be equal to or
greater than 16 inches. But this needs to be verified analytically because it might be
possible to mount them at shorter distance too, which, again is limited to a minimum
distance that need to be left between the back of the engine and chassis.

2.1.2 Forward Speed

Forward Speed is one of the most important parameters that influence both energy
requirements and work quality parameter like bite length. Forward speed is limited to
walking speed of the operator. This parameter too has been decided out of previous
experience and set to be 1.5 kmph.

2.1.3 Working Width (b)

Many Hand Tractors come with multiple work width option in which the existing
rotor can be extended on both sides to some extent. The two width values are chosen
on the basis of current agricultural plantation practices. Most of the plantation crops
are planted with distance between two rows at 1.5 feet (450mm) and 3 feet (900mm).
We have chosen to design a machine to operate on Curry Leaves field which has inter-
row space upto 450 mm.
2.1.4 Number of Flanges & Blades
Number of Flanges, which is a discrete number, in a rotor shaft is decided by cutting
width of the blade chosen and working width limitation. The cutting width (Lh) of the
blade in hand is 70 mm which, for a flange with blades mounted to both the sides,
along with clearance to the adjacent flange’s blade and flange thickness turns out to be
roughly 155 mm. From the working width, the chassis outer dimension where no
blades can operate needs to be subtracted and then divided by the above number. This
gives us the upper limit of number of flanges in the rotor shaft which is less than 3.

So, it is possible to mount 2 flanges in one shaft and the remaining untilled area is
covered by the following second rotor.

Figure 10 Multi-rotor Arrangement

Angular Displacement between blades is given (4) by:

Equation 2-1 Angular displacement between blades

360
𝐴0 =
𝑖𝑧𝑒

Where:

𝑖=no. of flanges, 𝑧𝑒 =no. of blades in a flange

 Parameter Value
w 35 mm
Lh 70 mm
Lv 183 mm
t 4 mm
𝜃 118.6°
Table 2-1 Blade Parameters

2.1.5 Working Depth

Working depth (denoted by ‘a’) to which the blades are tilling is a positive number as
far as work quality is considered but is highly limited by power requirements and soil
conditions. Commercial Power Weeders are having working depth upto 15 cm
(Mitsubishi VST Shakthi 130 DI—15HP). Considering operating depths of other
similar Power Weeders and Rototiller, we set the working depth to be 3 inches (7.62
cm).

2.1.6 Bite Length

As defined earlier, it is the distance between two successive blade cuts on soil surface
which is limited by forward speed. We have set this length to be slightly greater than 2
inches at 5.4 cm on the basis of a successfully operating Power Weeder. This length, if
set too low, will cause significant re-tillage and high power expenditure.

2.2 Work Calculation

2.2.1 Specific Work

Specific Work of a Rotary Tiller is the work done upon the soil per rotation per unit
volume of soil broken (7). It has two components to it: static 𝐴0 and dynamic specific
work 𝐴𝑏 . Specific Strength values are given in Table 1-1.
Equation 2-2 Specific Work

𝐴 = 𝐴0 + 𝐴𝑏 (Kg-m/dm3)

𝐴0 = 0.1𝐶0 𝐾0

𝐴𝑏 = 0.001𝑎𝑢 𝑢2 Or 𝐴𝑏 = 0.001𝑎𝑣 𝑣 2

𝑎𝑢 And 𝑎𝑣 are dynamic co-efficient interrelated by the following expression 𝑎𝑣 =

𝑎𝑢 𝜆2 . The value of 𝑎𝑢 has been experimentally determined to be 400 Kg.s2/dm3 and
𝐶0 =2.5
Figure 11 Specific
Work Calculation
Fig. 12 shows the screenshot of MS-Excel spreadsheet obtained by feeding Eq.2-2 and
varying lambda between 2 and 24 and forward speed between 0.72 and 7.2 kmph. We
can see that increasing both forward speed and lambda value has resulted in the
increase in specific work of the machine. These values are to be compared with the
performable work of the machine at the given working width.

2.2.2 Performable Work

Performable Work of the machine with respect to engine power is given (7) by:
Equation 2-3 Performable Work

7.5𝑁𝑐 𝜂𝑐 𝜂𝑧
𝐴𝑐 =
𝑣𝑎𝑏
Where:

𝜂𝑐 And 𝜂𝑧 are co-efficient for traction efficiency & power reservation respectively.

Feeding the equations in to MS-Excel and tabulating the difference between

performable and the closest specific work for each step in forward speed, we get
positive values upto a range only (0.4m/s in this case) after which the specific work of
the job exceeds engine’s performable work. The snippet of the Excel sheet has been
presented in the figure below:

v 0.2 0.4

4.5 32.282480 16.14 10.76

closest 'A' value 21.72 14.80 #N/A
Performable
b difference 10.57 1.34 #N/A
Work (A_c)
corresponding
24 6 #N/A
lambda value
Figure 12 Performable Work in positive range

The corresponding lambda value at which the closest specific work occurs has been
taken for further calculations. In our design, there are two forward speed steps
possible: 0.2 and 0.4 m/s whose corresponding lambda values are 24 and 6
respectively.

This method ensures that, for the equipments working width and depth, other values
are utilized to the maximum possible extent.
2.3 Design of Rotavator Elements
Having two forward speeds in hand, we can now choose one in which other
parameters like Bite Length and Rotor RPM are falling in the desired range.

2.3.1 Design of First Rotor Parameters

The design of multi-rotor system starts from fixing things with one of the rotors first
and then move on to the second one. A method has been proposed in section 2.3.2.2
to optimize second rotor’s parameters so that their net influence falls in our range.

2.3.1.1 Rotor Radius, Bite Length and RPM

For the given Rotor Radius and lambda value, the rotor rpm is given (7) by:
Equation 2-4 Rotor RPM

6000𝜆𝑣
𝑁=
2𝜋𝑅
Rotor radius is a parameter that we can use to optimize length of sliced soil and rotor
rpm but it has huge effect on pushing influence too6. Initially, a standard value of 13
inches (165.1 mm radius) has been chosen for rotor and then changed it to various
other values to arrive at suitable combination of Bite Length, RPM and number of
blades mounted to a side of the flange.

Variable Dependencies

Directly Proportional Variables Inversely Proportional

Term Formula
Letter Value Letter Value
C_0 2.5
Specific Work K_0 50
A_0 + A_b
'A'
a_u 400
a 0.762
Performable (7.5*N_c*n_c*n_z)/
N_c 4.524 b1 4.5
Work 'A_c' (vab)
b2 9
(6000*lambda *v)/(
Rotor rpm 'n' R 15.429
2*3.14*R)
Length of (2*3.14*R)/
R 15.429 Z 3
Sliced Soil 'L' (lambda *Z)
Rotor Shaft ((16*M_s)/(tau *3.1
R 15.429
Diameter 4))^0.33
a 0.762
Drawbar
v*D_a*a*b
Power b1 4.5
b2 9
Table 2-2 Variable Inter-Dependencies

6
As we shall see in coming sections
Table 2-2 shows us the chart of interdependent variables. As we can see, changing
number of blades mounted to a side of the flange (Z) is easier than changing rotor
radius because it is less interrelated with other variables and power requirements. But,
again, Z is a discrete number and is not completely independent of rotor radius. We
can change Z in the range of 2 to 4.

Length of
Forward Speed Forward Speed Closest 'A' lambda Difference
Rotor rpm Sliced Soil in
(m/s) (kmph) value closest in Work
cm

0.2 0.72 21.72 24 297 1.35 10.57

0.4 1.44 14.80 6 149 5.38 1.34
0.6 2.16 #N/A #N/A #N/A #N/A #N/A
0.8 2.88 #N/A #N/A #N/A #N/A #N/A
1 3.6 #N/A #N/A #N/A #N/A #N/A

1.2 4.32 #N/A #N/A #N/A #N/A #N/A

1.4 5.04 #N/A #N/A #N/A #N/A #N/A

1.6 5.76 #N/A #N/A #N/A #N/A #N/A

1.8 6.48 #N/A #N/A #N/A #N/A #N/A
2 7.2 #N/A #N/A #N/A #N/A #N/A
Figure 13 Optimized Parameters

After trying out various combinations, we arrived at the desired bite length for the
rotor radius of 15.429 cm for the first rotor with Z=3 and forward speed 1.44 kmph.

2.3.1.2 Rotor Shaft Diameter

Designing the rotor shaft has been done in line with the Design of Machine Elements
principles.

The maximum tangential force acting on the blade is given in Eq. 1-6. It can be re-
written in the form as below:

75𝑁𝑐 𝜂𝑐 𝜂𝑧
𝑇 = 𝐶𝑠
𝑢
This force generates a moment in the rotor shaft is calculated as given:

𝑀 = 𝑇 × 𝑅 = 2134.922 𝑘𝑔 − 𝑐𝑚

Considering the results obtained above, the rotor should be made from roll steel (AISI
302) having yield stress 𝜎𝑦 of 520 MPa. The allowable stress on the rotor is calculated
by the following (7) equation:
 0.577𝑘𝜎𝑦 300𝑘
𝜏𝑎𝑙𝑙𝑜𝑤 = =
𝑓 𝑓

Where:

k=stress concentration factor, 0.75

f=factor of safety, 2.

𝜏𝑎𝑙𝑙𝑜𝑤 = 1147.18 𝑘𝑔/𝑐𝑚2

Diameter of rotor shaft is given (7) by:

16𝑀
𝑑=√
𝜏𝜋

Feeding the obtained values, we get rotor shaft diameter of 21.15mm.

2.3.1.3 Proposed Analytical Model for Pushing Velocity of Rototiller

We make a number of assumptions for calculating the pushing influence of our
Rototiller as follows:

1. Tip reaction to penetration is ignored while calculating power division.

2. The power that is remaining after used for cutting and overcoming friction is
used to push the machine.
3. Pushing velocity is the result of pushing power spent upon the soil as tiller
force compensated for traction and efficiency losses.
4. Effect of number of flanges7 mounted to a side of the flange is ignored.
5. Effect of Blades’ shared clearance angle with ground is ignored.

Having set the assumptions, pushing power is then given as:

Equation 2-5 Pushing Power

𝑃𝑝 = 𝑃𝑇𝑂 𝑃𝑜𝑤𝑒𝑟 − (𝑃𝑐 + 𝑃𝑓 )

From Eq.1-9, PTO Power is obtained as follows:

𝑃𝑇𝑂 𝑃𝑜𝑤𝑒𝑟 = 6.5 × 0.87 × 0.80 × 0.7457 = 3.373 × 103 𝑊

Equation 2-6 Pushing Velocity

𝑃𝑝
𝑣𝑓1 =
(𝐹𝑡 × 𝜂𝑐 × 𝜂𝑧 )

7
More the number of flanges, lesser the time between successive cuts and hence there is lesser tendency for
penetration into the ground at any given rpm. The rotor more acts like a cylinder.
Feeding this PTO Power into equations explained in section 1.1.6.3 and Eq.2-6, an
Excel spreadsheet is created. Fig.15 shows the snippet of the spreadsheet. The
influence pushing velocity has been found to be 5.19 kmph. This speed is much higher
than our target speed which is used in bite length calculations.

Blade Parameters
Calculated & Empirical Parameters (Automatic)
(Enter Values in meter)
Adhesion Stress
Blade Span at Frictional
0.037 b/w Blade and 7.93E+03 514619.8819
Bottom Stress
Soil

Overall Angle of Blade Cutting

0.183 30.42147197 16.764
Vertical Incidence Force

Overall Area of Frictional

0.044 0.0033528 837.8011677
Horizontal Working Width Force (N)

Area of Friction Cutting

Blade Angle 0.001628 40.2336
Surface Power
Clearance Frictional
Tiller Force 1405.6445 2010.722802
Angle Power
Angular
Normal Stress
Displacement b/w 15 863418.00
blades (N/m-m)

with no. of Pushing

at L value (in
5.4 blades on one 3 Velocity 5.191248903
cm) of
side of flange (kmph)

and Rotor
at rpm 149 15.429
Radius (in cm)

Figure 14 Calculation of Pushing Velocity

2.3.2 Design of Second Rotor

Before moving on further, we need to list out all the variables and appreciate the inter-
relatedness between them so that we can better construct our model.
2.3.2.1 Interdependencies of Various Parameters

Pushing Velocity
Frictional Power Cutting Power Tiller Force
• Blade Span • Cutting Width • RPM (inversely)
• Overall Horizontal • Working Depth • Rotor Radius
Blade Length (inversely)
• Angle of Incidence

RPM Rotor
Radius

Roto
2.3.2.2 Proposed Analytical Model for Second Rotor Design
Here, we are making another set of assumptions upon which we are basing our new
analytical model.

1. The influence of first and second rotor has net influence on each other and their
difference is equal to the final forward velocity.
2. Bite Length of the two rotors are equal and equal to the bite length obtained
when the machine is moving forward at the target speed.
3. Effect of number of flanges8 mounted to a side of the flange is ignored.
4. Effect of Blades’ shared clearance angle with ground is ignored.
Equation 2-7 Target Influence forward speed

𝑣𝑓1 − 𝑣𝑓2 = 𝑣

8
More the number of flanges, lesser the time between successive cuts and hence there is lesser tendency for
penetration into the ground at any given rpm
Where:

𝑣𝑓1 And 𝑣𝑓2 are influence pushing velocities of first and second rotors respectively.

Feeding suitable values into Eq.2-7, we get

𝑣𝑓2 = 3.7512489 𝑘𝑚𝑝ℎ

This value is fed into the relation similar to one expressed in Eq.2-6:
Equation 2-8 Pushing Velocity of second rotor

𝑃𝑝
𝑣𝑓2 =
(𝐹𝑡 × 𝜂𝑐 × 𝜂𝑧 )

The expression of Tiller Force given in Eq.1-10 is fed into the above equation and the
obtained resultant expression is as follows:

𝑃𝑝2 × 𝑁2 × 𝑅2 = 21903.4244

The L.H.S. of the above expression is termed as Ideal Product of Rotor Parameter and
Pushing Power. It has two parameters N and R under our control which can be tried
out in different combinations to get as near as possible to the ideal value.

W.K.T bite length has to be kept equal to the bite length of first rotor assuming that
the machine moves forward at the target speed. This does not necessarily mean that
both the rotors are having same kinematic parameter𝜆.

From Eq.1-8, we get

2𝜋𝑅2
= 0.054
𝜆2 𝑧2

Modifying the above relation, we can now express rotor radius in terms of lambda and
number of flanges mounted to one side of the flange.
Equation 2-9 Second rotor radius

0.054
𝑅2 = 𝜆 𝑧
2𝜋 2 2
Where:

𝑧2 is a discrete set with very limited range and 𝜆2 can be varied more comfortably
within a broad range. Feeding Eq.2-9 and other related equations into our spreadsheet
we obtain the following chart of data.
 Figure 15 Chart of Second Rotor Parameters

Product of Rotor
Rotor Tiller Cutting Angle of Normal Frictional Frictional Frictional Pushing
lambda R N Parameter and
Parameter Force Power Incidence Stress Stress Force Power Power
Pushing Power

2 7.6433121 0.034269 223.0368141 4214.796 13.418 #NUM! 2588940.8 #NUM! #NUM! #NUM! #NUM! #NUM!

3 11.464968 0.051404 223.0368141 2809.864 20.127 -28.85539 1725960.6 -943096 -1535.36 -1843.37 5196.787 59580.99196

4 15.286624 0.068539 223.0368141 2107.398 26.836 -6.421349 1294470.4 -137754 -224.263 -359.002 3705.713 56647.84586

6 22.929936 0.102808 223.0368141 1404.932 40.25401 15.00716 862980.28 239283.5 389.5535 935.4025 2397.89 54983.47066

7.6 29.044586 0.130223 223.0368141 1109.157 50.98841 24.52238 681300.22 318740.8 518.91 1578.287 1744.272 50661.65266

10 38.216561 0.171346 223.0368141 842.9591 67.09001 33.74759 517788.17 353876.4 576.1108 2305.612 1000.845 38248.83599

12 45.859873 0.205616 223.0368141 702.4659 80.50801 39.02608 431490.14 357672.1 582.2902 2796.411 496.6281 22775.30235

12.5 47.770701 0.214183 223.0368141 674.3673 83.86251 40.12828 414230.54 357097 581.3539 2908.244 381.4402 18221.66513
16 61.146497 0.274154 223.0368141 526.8495 107.344 46.2478 323617.61 345962.3 563.2267 3606.479 -340.276 -20806.69503
18 68.789809 0.308424 223.0368141 468.3106 120.762 48.87022 287660.09 337338.2 549.1866 3956.149 -703.365 -48384.31301

20 76.433121 0.342693 223.0368141 421.4796 134.18 51.07121 258894.08 328454.2 534.7235 4279.958 -1040.59 -79535.60275

22 84.076433 0.376962 223.0368141 383.1632 147.598 52.95285 235358.26 319729.8 520.5202 4582.901 -1356.95 -114087.6876

24 91.719745 0.411231 223.0368141 351.233 161.016 54.58567 215745.07 311355 506.886 4868.573 -1656.04 -151891.8115
Comparing the last column with our ideal product of rotor parameter and pushing
power, we get that it gets nearest to the ideal value at lambda equaling 12.5. The
matching RPM and Rotor radius are 223 and 214.2 mm respectively.

From the chosen lambda’s corresponding pushing power value and tiller force, we can
calculate the influence pushing velocity from Eq.2-8.

𝑣𝑓2 = 3.12 𝑘𝑚𝑝ℎ

2.3.2.3 Final Forward Velocity and Allowance for Depth Skid Influence
Final forward velocity is obtained by feeding the obtained pushing influence of second
rotor to Eq.2-7. It may be noted that this value has to be kept slightly higher by a
certain percentage which can be controlled by the depth skid. This allowance is called
the depth skid allowance.

𝑣𝑓 = 2.07 𝑘𝑚𝑝ℎ

This value is 30% higher than the intended forward speed that needs to be left to the
influence of the depth skid. This allowance is essential because usage of depth skid for
the purpose of maintaining operating depth is inevitable and in the process, it will
have some negative traction which should be compensated in calculations.

2.3.3 Plotting the Cutting Trajectory of the Tiller Blade

An Excel graph is created for this purpose of plotting the cutting trajectory. Apart
from the cutting curve, 2 straight lines representing the base line representing the
maximum depth the blades are tilling and the ground line are fed into graph data. It is
decided to mark points at every 45 degrees and the time interval is calculated
accordingly as follows:
Equation 2-10 time interval

𝜃
𝑡=
𝜔
At 149 rpm of the first rotor, angular velocity is about 15 radians per second.

𝜃 0 45 90 135 180 225 270 315 360

t 0 0.45 0.10093 0.15139 0.20186 0.25232 0.30279 0.35325 0.40372

Table 2-3 Time Intervals at angles through single rotation

These values of time are fed to Eq.1-7 to get the corresponding x and y coordinates.
Note that when the values are fed to the equation as it is, it will yield profile of blade
starting from x-axis at zero degrees. For other blades’ starting points, we need to shift
the curve by respective angles.
The second and third blades in clockwise direction from the first one are, in the first
rotor containing three blades mounted to a side of the flange, at an angle of 120
degrees (2pi/3 radians) and 240 degrees (4pi/3 radians) respectively.

Considering and accounting for all the above things, the cutting trajectory of the three
blades mounted to the side of a flange in the first rotor is plotted in Excel as follows:

Figure 16 Cutting Trajectory plotted

2.3.4 Gross Concept Error Alternate Provisions

We decided to accept the fact that, even though we have done careful analytics in the
subject and brought out an acceptable model, this work is not previously verified
experimentally and there might be so many considerations we might have missed out
to account for. This is also partly because we have not done and verified any previous
analytics in the subject. So we deliberated during design stages and provided a crucial
‘escape’ or alternate provision to make the machine work even in the case of our
calculations going completely wrong.

The arrangement is that the back rotor flange containing lesser number of blades and
rotating opposite to the vehicle’s forward motion can be swapped to be fitted to the
forward rotor rotating with down-cut action. This ensures that the machine will work
even if our calculations turned out to be exactly opposite to the working reality.

2.4 Determination of Transmission Ratio

The front and back rotors are rotating at rpm of 149 and 223 respectively opposite to
each other. This means that there is a need for separate drives to each rotor and there
must be a gear pair in direct mesh before the second rotor so that it rotates in opposite
direction. Engine must be kept at a certain height and so is the main pulley that needs
to be kept above the mudguard with certain clearance. The height at which the main
pulley is mounted gives us the height from which drive reaches rotor shafts.
Considering mudguard’s position which must be kept at least 2 inches spaced from the
bigger second rotor’s blade tip (428mm from the ground) and a clearance distance
after which the main pulley can be mounted, it is unlikely that any other type of drive
than chain and sprockets will be possible between main pulley and rotor shafts inside
the housing.

The maximum size of pulley that can be safely operated as a main belt pulley is 13
inches and the minimum number of teeth in a ½” sprocket is 12. The maximum
number of teeth in the sprocket mounted to the rotor shaft is limited by ground
clearance with the rotor housing and therefore it is set to not exceed 30 teeth. Engine’s
base rpm is 2100 rpm.

Now, from the above information we can say that the main-pulley shaft’s rpm is
calculated as follows:
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟𝐸𝑛𝑔𝑖𝑛𝑒 𝑃𝑢𝑙𝑙𝑒𝑦
𝑁𝑚𝑎𝑖𝑛−𝑠ℎ𝑎𝑓𝑡 = 𝐸𝑛𝑔𝑖𝑛𝑒 𝑅𝑃𝑀 ×
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟𝑀𝑎𝑖𝑛 𝑃𝑢𝑙𝑙𝑒𝑦

2
𝑁𝑚𝑎𝑖𝑛−𝑠ℎ𝑎𝑓𝑡 = 2100 × = 323
13
This rpm needs to be brought down to 149 rpm for the first rotor in the same direction
and to 223 rpm for the second rotor in the opposite direction. The transmission ratio
and number of sprocket difference between main shaft and first rotor shaft is
calculated as:
𝑁𝑅1
𝑖𝑅1 = = 0.461
𝑁𝑚𝑎𝑖𝑛−𝑠ℎ𝑎𝑓𝑡

𝑇𝑚𝑎𝑖𝑛−𝑠ℎ𝑎𝑓𝑡
𝑇𝑅1 = = 26
𝑖𝑅1

It is decide that the gear pair used to change direction to not have any reduction
functionality to it. This is because, in a reduction pair, the pinion runs more number of
cycles and therefore be made of stronger material for medium and high power
applications (8). We need not necessarily complicate things and so buying ready-made
gears made as textile machinery spares is considered time-saving and quicker option.
This means that the entire reduction for the second rotor comes in chain sprockets.
𝑇𝑠𝑒𝑐𝑜𝑛𝑑−𝑠ℎ𝑎𝑓𝑡 13
𝑇𝑅2 = = = 19
𝑖𝑅2 0.69
 3 MODELING AND FABRICATION
Creo 2.0 is the software we used to model the entire machine including all sub-
systems except the engine. The engine’s outer dimensions are taken and an equivalent
box is modeled and used in all areas. Since the working width is slightly lower than
the distance between two outer blades in both sides when the adjacent blades are
mounted with positive clearance, a slight overlap is given in transverse direction. This
means that there is a slight re-tillage occurring in the soil which need not be brought
into design calculations.

3.1 CAD Modeling and Preparation

Body width must be limited as far as possible because it is an area where blades are
not able to operate. The side plates of the housing are made from 4mm sheets and
therefore the available space inside the housing is obtained by subtracting it from the
outer dimension.

The engineering drawings of all CAD models are attached as separate sheets in
required places herein.

The shafts, in general, should have a central step slightly greater than the inner race
diameter of the 6206 bearing being used so that the shaft can be locked at the desired
spot. On both sides of that central step, there is a secondary step whose outer diameter
holds the bearing. The length of this step must be equal to the bearing and oil seal’s
widths plus the step in the bearing housing separating it. The standard dimensions of
different bearings (9) are referred to before starting to model the components. After
the bearing seating step, there is another step with slightly lesser diameter on both
sides of the shaft that lets us to assemble bearing over the shafts with ease. The length
of the two shafts in the top of the rotor housing from which individual rotors below
receive power are slightly different since the main shaft has to seat the pulley whereas
the other shaft need not to. The rotor flanges are welded to a sleeve which, in turn, is
bolted to the rotor shaft so that they can be easily dismantled and assembled.

The bearing housings are designed in line with the shaft design. On the inner surface,
there is a portion allocated for bearing and then there is a step after which the oil seal
can be assembled from the outside. There are three kinds of housings used in this
machine based on the outer step size that depends upon the place where it is going to
be mounted.

The rotor housing is to be laser cut in a 4mm sheet whose peripheral covering plates
are 6mm plates. The right hand side plate (as viewed from the front of the machine)
has two bottom lids bolted to the housing plate whereas the left hand side plate has a
void for mounting the gear-pair cover. The arrangement is such that the bearing
housings are not hold by the housing plate directly but through the lids bolted to it.
3.2 Purchase of Components
Gearwheels, Sprockets and Pulleys have been purchased at Coimbatore in a textile
machinery spares store. There is a range of ready-made gearwheels and sprockets
available there with case-hardened surface for gearwheels.

We decided to buy a 38 teeth gear of module 2.5 with tip diameter 100 mm so that the
center distance stands at 95 mm. This is essential because the center distance has to be
greater than the radius of the two sprockets in the two respective shafts combined.

Figure 17 Sprockets purchased

Figure 18 Gearwheels purchased

3.3 Laser Cut and Lathe Operation
The prepared CAD files are then converted to dwg files from which it can be exported
to 2D dxf format. This dxf files are then given to a manufacturing center in Salem for
laser cutting. The sprockets, gears and pulleys along with shafts, sleeve and bearing
housings are given to another manufacturing center specializing in Lathe operations.

3.4 Assembly and Welding

C-clamps of suitable sizes in many numbers are bought from a store in Coimbatore
which is to be used to clap the assembly tightly while welding. This is very much
essential since any distortions occurring during welding will cause center distances
between axes of bearing to be unequal thereby causing unnecessary bearing loads.

References
1. Design Optimization of Rotary Tiller Blade using Specific Energy Requirement.
Mandal, Subrata Kumar, et al. 4, 2016, International Journal of Current
Engineering and Technology, Vol. 6. E-ISSN 2277 – 4106, P-ISSN 2347 – 5161.

2. Marenya, Moses Okoth. Performance characteristics of a deep tilling rotavator.

Built Environment and Information Technology, University of Pretoria. Pretoria : s.n.,
2009. PhD Thesis.

3. Optimization of Design Parameters for Rotary tiller's Blade. Mandal, Subrata Kr,
Bhattacharya, Dr. Basudev and Mukherjee, Dr. Somenath. IIT Roorkee : s.n.,
2013. 1st International and 16th National Conference on Machines and Mechanisms
(iNaCoMM2013).

4. IIT Kharagpur. A Course on Farm Machinery. Kharagpur, India : s.n.

5. Development of rotary weeder blades by Finite Element Method. Mr. Mahesh

Gavali and Mr. Satish Kulkarni. 6, s.l. : www.ijsret.org, 2014, International Journal
of Scientific Research Engineering & Technology (IJSRET), Vol. 3. ISSN 2278 –
0882.

6. Sakai, Jun. Designing Process and Theories of Rotary Blades. s.l. : Mie
University.

7. Rotary Tiller Design Proportional to a Power Tiller using Specific Work Method
(SWM). Komarizadeh, Mohammad Hasan, Zareiforoush, Hemad and Alizadeh,
Mohammad Reza. 9, 2010, Nature and Science, Vol. 8.

8. Prabhu, T J. Design of Transmission Elements.

9. Bearing Works Inc. [Online] www.bearingworks.com.