CHAPTER THREE

3.0 MATERIALS AND METHODOLOGY

 MATERIALS.

The material the machine will be built out of is one of the design's physical
considerations. When choosing materials, the availability of the materials is more
crucial than other considerations like quality, appropriateness, cost, strength and
stiffness, corrosion resistance, and most crucially, food safety. By choosing the
right material, one may predict how a certain metal will behave under particular
environmental conditions and how it will respond to loads and pressure that are
applied to it.

The Materials used for the project and their function are stated below:

 Frame

This is the platform on which all other components are mounted on. This part
must be able to withstand dynamics stress and torsional stress. It must be a
material with high stiffness. Angle iron made of mild steel was used because it
suits the purpose of the job and it is also cheap and easy to get.

 Housing

This is the compartment where the crushing of the grains takes place. This part
must not be made of material that is reactive with any grain to avoid
contamination of the product produced. For the purpose of this study mild steel
was used after a comparison of various materials.

 Housing Cover

This holds the hopper and the statics crusher and it made of mild steel

 Hopper

This is the particular place in the machine through which the grains are fed into
the crushing unit for grinding of the grains. It has the shape of a truncated
pyramid and it is made of mild steel plate of about 6mm.
  Dynamic crusher

The dynamic crusher is connected to the shaft and rotates at the relatively same
speed as that of the shaft. This component performs the most essential part of the
grinding. It crushes the grains as it rotates. Due to its purpose, the component is
required to exhibit hardness properties, therefore, the steel used for the component
went through heat treatment after being made.

 Static rusher

The static crusher is connected to the housing cover. It purpose is similar to that
of a dynamics crusher. It is static while dynamic crusher rotates around it to crush
any material trapped between them. Due to its purpose, the component is required
to exhibit hardness properties, therefore, the steel used for the component went
through heat treatment after being made.

 METHODOLOGY

The machine frame was fabricated using angle bar to give rigidity and stability
required to withstand various loads acting on the machine and vibrations resulting
from the loading effects. The shaft components were fabricated from mild steel
because it can be easily rolled and drawn into shape and it’s relatively low cost
and availability in the market. It has greater strength giving it undeniable
advantages. A number of factors were taken into consideration, some of which
include; mechanical properties such as load and stress consideration, strength and
rigidity of the design, motion of parts, material selection. Also, ergonomics
(designing to suit human use) was carefully considered in the design. However,
attention was given to the primary function of the grain grinding machine, which
is grain size reduction. The machine design drawings were developed using
AUTODESK INVENTOR 2023 version.
 Fig 3.1: Model of the grain grinding machine

3.1 DESIGN CONSIDERATION

Different design factors were taken into consideration. These are as follows:

 DURABILITY

The parts of machine are chosen that they may last for longer period before any
sign of damage may be noticed.

 PORTABILITY

The machine design was made in such a way that the machine will be easily
transported.

 STRENGTH

Before any construction work could be done, the stress produced by the load on
the machine parts should be considered. Therefore the need to ensure the machine
has enough strength to withstand both compressive and shear stress

 CORROSIVE RESISTANCE
Machine parts must be prevented from rusting. This was ensure by using
corrosion resistant materials and coating of other materials with glossy paint.

 AVAILABILITY

This is one of the most crucial aspects to take into account while choosing
materials. To make construction and maintenance easier, the materials must be
accessible and affordable. Regarding the aforementioned fact, the materials
utilized in the manufacture of this machine were sourced locally at a neighboring
market in Owode Onrin, Lagos State.

 STABILITY

This is a major focus point for improvement in the machine. This is the ability to
remain stable and rigid during crushing/grinding operations. This was put into
consideration when designing the machine. Also, the crushing force must be
balanced with another weight and this results in the position of an electric motor
at the exact point fit to counter the force.

 AFFORDABILIITY

The machine was fabricated with readily available materials in the locality:
thereby no need to settle for highly expensive imported materials that could raise
the cost of production of the machine, hence make it unaffordable to people.

 WEIGHT

To determine the average weight of grains. Maize, millet were picked randomly
and each weight was also recorded.

 STRENGHT IN GRAIN

Grain hardness is an important property of grains and is of interest to both

producers and consumers of grains. Cutting and cracking of grains provides
breakage evaluation and consequently crushing efficiency.
  MOISTURE CONTENT

Grain water content should be reduced to about 5% or less. It is therefore

important to measure before grinding. Moisture reduces the rate of crushing
therefore reduce the efficiency of the machine.

 SHAPE AND SIZE

These are closely related to physical factors of grinding efficiency that influence
the grinding capacity. The size and the shape of the grain needs to fit into the
space between the static and dynamics crusher.

3.2 DESIGN ANALYSIS AND CALCULATION

 The volume of Hopper

The volume of hopper can be calculated using equation below:

……………………………………………………………..(1)

where Vct = Volume of Cuboid having the hopper top, has its length and breadth

Vcb = volume of Cuboid having the hopper, bottom has its length and breadth

Note: the height of cuboids for calculating Vct and Vcb is the vertical height of
the hopper (250mm).

Therefore, Vct = 250 x 280 x 250

= 17,500,000mm3

Vct = 0.0175 m3

Vcb = 93 x 140 x 250

Vcb = 3,255,000 mm3

Vcb = 0.003255 m3

Therefore,
Volume of hopper =

Vh = 0.0038675m3

 Determination of Shaft Speed

The transmission system used is belt transmission via a pulley (specifically v-belt
selection), where the rotating force generated by electric motor serves as the
driver. Thus, to calculate the shaft speed, the following parameters were
considered

…………………………………………………………(2)

 Determination of the Belt Contact Angle

The belt contact angle is given by ((Hollowenko et al, 2004))

………………………………………………………(3)

The angles of wrap for the pulleys are given as;

………………………………………………(4)

 Determination of Belt Tension

The belt tension can be determined using the relationship below (Khurmi and
Gupta, 2008).
Maximum tension in belt

……………………………………………………………..(5)
Centrifugal tension in belt

………………………………………………………(6)

To get tension in slack side, the relationship shown in Equation (6) can be used

……………………………………..(7)

But,

= centrifugal force acting on the belt.

The Linear velocity (V) of the belt is given as

…………………………………………………………(8)

 Determination of the Torque and Power Transmitted to the shaft

Power transmitted to the shaft is given by

……………………………………………………(9)

The torque exerted on the driving pulley is given by

………………………………………………….(10)

 Determination of the Crusher weight

From the equation,

……………………………………………………….(11)

 Determination of the Centrifugal Force Exerted by the Crusher

Centrifugal force exerted by the Crusher can be calculated as given by:

…………………………………………………………(12)
The angular velocity of the Crusher is given by

………………………………………………………(13)

 Shaft Design
The design of power transmitting shaft basically consists of the determination of
the correct shaft diameter to ensure satisfactory strength and rigidity, during its
operation under various loading and working conditions. Shafts are usually
circular in cross-section, and may either be hollow or solid.
The following are considered during shaft design;
 The diameter of the shaft
 Length of the shaft.
 Reaction on bearing resting on shafts.
 Size bearings.
 Bending and Tensional Moments.
 CHAPTER FOUR

4.0 RESULTS

After the fabrication of the project, there is need to test the machine with grain to
evaluate its performance. For the purpose of this project dry maize was chosen as
the grain to be used for testing.

A 4.8 kg of dry maize was fed into the hopper and the maize was slowly fed into
the grinding chamber to prevent clogging on the screen. The time taken for
grinding was noted and also the mass of the recovered maize after grinding was
recorded. As shown in Table 1, this was repeated five times and the average time
and mass values were used for calculation.

Table 1: Tabulated value of the result from testing using maize.

Trial Mass of maize before Mass of maize after Time taken

grinding grinding (s)
(kg) (kg)

1 4.8 4.08 288

2 4.8 4.04 307.2

3 4.8 4.00 302.4

4 4.8 4.12 300

5 4.8 4.08 302.4

Average 4.8 4.064 300

 4.12

4.1

Mass of maize after grinding (KG)

4.08

4.06

4.04

4.02

3.98

3.96

3.94
1 2 3 4 5
Trials

Fig 4.1: Bar chart showing the output of grains for each trial

310

305
Time taken to Crush (s)

300

295

290

285

280

275
1 2 3 4 5
Trials

Fig 4.2: Bar chart showing the time taken to grind the grains for each trial

Average mass of the dry maize before grinding = 4.8 kg

Average mass of the dry maize after grinding = 4.016 kg
Average time taken = 300 seconds
Crushing Efficiency

= 85%

= 15%

Crushing Capacity =

Where MI = Average mass of maize crushed in Kg

T = average time taken to crush it in Hours

Crushing Capacity =

= 48.6 Kg/hr

4.1 FINDINGS/OBSERVATION

The performance tests conducted indicated that high value of crushing efficiency
is attainable. Series of test were conducted with 4.8kg of dry maize and the
crushing efficiency was found to be 85%, crushing loss of 0.15% and crushing
capacity of 48.6kg/hr. From the test result, it was observed that the modified
crusher has a higher capacity and efficiency.
4.2 MAINTENANCE

 Change the belt when it has less tension.

 Clean machine after each use.
 Ensure that all bolts on machine are tightened properly.
 Lubricate all rotating parts before use to avoid wear of the machine parts
  Always ensure the housing is not wet with water or any moisturized
substance

4.3 INSTALLATION
The following points should be considered during the installation of the machine
 Machine should be installed on level ground
 Machine should be installed at a well- ventilated spot
 Machine should be installed near a source of natural light
 Machine should be observed carefully before operation
 Plug wire to socket and switch on the power supply

4.4 COST ESTIMATION

Table 2: Bill Of Engineering Measurement And Evaluation (BEME)

S/N Component part Material Quantity Total (#)

1 Hopper Mild Steel 1/4 sheet 15,000
Workmanship 10,000

4.5 PERFORMANCE EVALUATION

The performance test of the machine was carried out after the fabrication was
completed in order to know if it is functioning according to the detailed design
specifications. Dry maize was obtained weighed using weight balance scale. The
machine was operated for three minutes to allow speed to stabilize. The dry maize
was introduced into it through the hopper for another five minutes to check for
vibration, misalignment in the shaft connection, other irregularities of the machine
and finally the performance of the machine. The stop watch was used to monitor
the time. Series test were conducted with the machine, and the crushed maize was
collected into a scale, weighed and recorded using the weight balance scale.

CHAPTER FIVE
5.0 DISCUSSION
The designed grains grinding machine (Crusher) reduced processing losses,
produce flour with longer shelf life (dry flour), enhance greater consumer choice,
ensure new markets for domestic cereals and legume crops, and reflect a more
effective response to changing market requirements and increase food security for
Nigeria. The major components of the machine are shaft, statics crusher,
dynamics crusher, bearing, Housing and electric motor. From the design
consideration and analysis portability, reliability, safety, serviceability and cost of
construction were given due considerations. All components were fabricated
using locally sourced materials.

5.1 CONCLUSION
The preliminary tests carried out on the operated grains grinding machine
(Crusher) confirm that it operates satisfactory. The static crusher is stationary but
the dynamic crusher are the adjustable types, making it possible to mill grains
small enough to pass through the crushers with an aperture size of 3mm. The
environmental pollution associated with the use of conventional grinding can be
easily controlled. Thus there is no health hazard experienced by the operator of
the new machine. It is hoped that the commercialization and wide spread
application of the grains grinding machine (Crusher) will contribute significantly
to the growth of the agricultural and solid mineral processing industry in Nigeria.

5.2 RECOMMENDATION
On the completion of the project and in spite of effective performance, the
following will be recommended for effective operation and improved operation.
 Addition of more teeth to the crusher to improve the machine effiecicncy
 Incorporating a spring loaded mechanism to adjust the machine to crush or
grind to a specified size
 Production for large scale food processing industries.
 Addition of a method to separate the grinding powder and the granules
separate.
5.3 FUTURE WORK
The grains grinding machine is an essential machine in food processing of
agricultural sector. Therefore more research should be done in other to devise
another method of grinding grains to the desired size. Therefore it would be
suggested that more research should the carried out on this area.