DECLARATION

We hereby declare that the research paper "design and manufacturing of versatile brush
cutting machine" that we submitted is based on our own actual and original work. Any
references to other people or institutions' work, as well as material received from other sources,
have been properly cited and referenced. We also guarantee that the research work has not been
published or submitted for publication elsewhere, and that it will not be published in the future.

Abel Samuel

Abel Silas

Aklilu Brihane

Atrsaw Aderajew

Signature

i
 ACKNOWLEDGEMENT

First and foremost, we want to express our gratitude to God. Many stakeholders contributed to the
design and construction of the versatile brush cutter in this project, also we would like to express
our gratitude to the Metal Industry Development Institute (MIDI) for providing us with this
opportunity to work in the company. The company also allowed us to use its production
equipment for our project. We'd also want to thank Addis Ababa Science and Technology
University (AASTU) for allowing us to operate here. It serves as the theoretical foundation for
our future efforts. We also owe a debt of gratitude to our advisors, Mr. Yonas, Mr. Sultan, and
Mr. Mekbib, who assisted us in all facets of this project, both practical and theoretical. All of the
workshops' machinists assisted us in every step of the manufacturing process. They also provide
instruction and training on how to operate these machines. Finally, we would like to express our
gratitude to our advisor, Mr. Surafel, for his assistance during our internship.

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 ABSTRACT

. Brush cutters are mechanical devices that are used to chop common things like grass and tiny
and large tree branches. The main objective of this project is on the design, manufacture, and
pricing of a multifunctional brush cutter As a result, our goal is to design and build a brush cutter
machine that can be used to reap grass in a simple and attractive manner. Specifically, to develop
the battery-powered versatile brush cutter's available mechanism, geometry, and dimensions. The
customer's request for product specifications is fulfilled. The information acquired from the
consumer is used to create various concepts that would help the customer achieve his or her goal.
The best notion is then chosen from among these concepts. Detail design and analysis method is
used in this project. The materials used in each component are determined by the product's cost,
availability, and intended usage. During the design phase, the stress acting on important
components is examined using numerical analysis and solid works simulation. The simulation
result is included in the document's detail design, whether the component fails or not. The
available results from the simulated labor allowed us to reach a conclusion on each part. In the
geometrical and kinematic analysis, the product's final dimension is determined. The 3D
geometry is then built using solid worksV2021. It covers all of the machine's components,
subassemblies, and final assembly. After determining the machine's final geometry, the
manufacturing stage is followed to demonstrate each step in the prototype's creation. The cost of
the product is examined to determine the fundamental difference between this work and other
designs imported into the country. The numerical and software analysis results allowed the
project to be completed based on the target and goal.

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 TABLE OF CONTENTS
DECLARATION...................................................................................................................i

ACKNOWLEDGEMENT.....................................................................................................ii

ABSTRACT...........................................................................................................................iii

List of figures.........................................................................................................................vii

List of tables...........................................................................................................................viii

NOTATION...........................................................................................................................ix

CHAPTER 1..........................................................................................................................1

INTRODUCTION.................................................................................................................1

1.1 Back ground overview............................................................................................1

1.2 Statement of the problem........................................................................................1

1.3 Objective.................................................................................................................2

1.3.1 General objective.......................................................................................................2

1.3.2 Specific objectives.....................................................................................................2

1.4 Study Methodology.................................................................................................2

1.5 Scope of the study..................................................................................................3

1.6 Significance of the study.........................................................................................3

1.7 Limitation................................................................................................................3

CHAPTER 2..........................................................................................................................4

LITERATURE REVIEW......................................................................................................4

2.1 Introduction..................................................................................................................4

2.2 Literature survey.....................................................................................................5

2.2.1 Types of brush cutters................................................................................................5

CHAPTER 3..........................................................................................................................8

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PRODUCT PLANNING AND METHODOLOGY OF THE RESEARCH.........................8

3.1 Planning methods....................................................................................................8

3.2 Data collection and Identification of customer need...............................................8

3.2.1 Primary data collection method.................................................................................8

3.3 Concept generation and idea selection....................................................................9

3.3.1 External search result of multi-purpose cutting machine.................................9

3.3.2. Internal search on the multipurpose cutting machine................................................10

3.3.3 Systematical assessment............................................................................................12

3.4 Evaluation and Concept selection...........................................................................14

3.4.1 Concept screening......................................................................................................14

3.4.2 Concept scoring.........................................................................................................15

3.5 Fictional analysis.....................................................................................................15

3.5.1 Overall function.........................................................................................................16

3.5.2 Functional decomposition.............................................................................................16

3.6 Research and embodiment construction..................................................................16

3.6.1 Force transfer and motion transmission method........................................................17

3.6.2 Product Architecture..................................................................................................17

3.6.3 Configuration Design................................................................................................18

3.6.4 Parametric design.......................................................................................................19

CHAPTER 4..........................................................................................................................21

DESIGN AND ANALYSIS OF BRUSH CUTTER COMPONENTS.................................21

4.1 Selection of suitable materials for machine components........................................21

4.2 Analytical (hand calculation) analysis for major components................................22

4.2.1 Analytical (hand calculation) analysis for main shaft................................................22

4.2.2 Analytical (hand calculation) analysis for adjustment shaft......................................24

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4.2.3 Analytical (hand calculation) analysis for rotary blade.............................................26

4.2.4 Analytical (hand calculation) analysis for dc motor efficiency.................................27

4.2.5 Analytical (hand calculation) analysis for bolts............................................................28

4.4.1 Analysis of pure bending stress for the main shaft....................................................31

4.4.2 Analysis of combined bending and torsional stress on adjustable shaft....................34

4.4.3 Analysis of compression stress for the aluminum plate.............................................36

CHAPTER FIVE...................................................................................................................40

MANUFACTURING PROCESS AND ECONOMIC ANALYSIS.....................................40

5.1 Method used for manufacturing..............................................................................40

5.1.1 Manufacturing Main shaft.............................................................................................40

5.1.2 Telescopic shaft............................................................................................................41

5.1.3 Adjustable shaft............................................................................................................41

5.1.4 Sliding plate...............................................................................................................41

5.1.5 Locking plate................................................................................................................42

5.1.6. Dc motor holder...........................................................................................................42

5.1.7 Couplings......................................................................................................................43

5.1.8 Handle...........................................................................................................................43

5.1.9 Wheel RHS................................................................................................................44

5.2 Economic analysis...................................................................................................44

5.2.1 Market survey............................................................................................................45

5.2.2 Cost of each type of material.....................................................................................46

5.2.3 Cost Comparison between this product and related products....................................53

CHAPTER 6..........................................................................................................................54

RESULT AND DISCUSSION..............................................................................................54

6.1 Result.......................................................................................................................54

vi
6.1.1 Analytical (hand calculation) analysis analysis result...............................................54

6.1.2 Simulation result........................................................................................................55

6.2 Discussion...............................................................................................................55

6.2.1 Stress distribution for Main Shaft..............................................................................56

6.2.2 Stress distribution For Adjustable Shaft....................................................................57

6.2.3 Stress distribution for Aluminum Couplings.............................................................57

CHAPTER 7..........................................................................................................................59

CONCLUSION AND RECOMMENDATION.....................................................................59

7.1 Conclusion...............................................................................................................59

7.2 Recommendation.....................................................................................................59

7.3 Future study.............................................................................................................60

REFERENCE.........................................................................................................................61

APPENDICES.......................................................................................................................62

Appendix A Interview Question........................................................................................62

Appendix B Bill of Material..............................................................................................64

Appendix C Concept Screening Matrix.............................................................................65

Appendix D Concept Scoring Matrix................................................................................66

Appendix E Relative Importance of the Needs..................................................................67

Appendix F Marginal and Ideal Value...............................................................................68

vii
 List of figures

Figure 1.1 study design.....................................................................................................................2

Figure 2.1 cylindrical mowers [6].....................................................................................................6
Figure 2.2 gasoline cutters [5]...........................................................................................................6
Figure 2.3 electrical mowers [1].......................................................................................................7
Figure 3.1 Systematical assessment................................................................................................12
Figure 3.2 functions decomposed to sub functions.........................................................................16
Figure 3.3 schematic diagram with applied force and acceleration................................................17
Figure 3.4 product schematic and clustering elements...................................................................18
Figure 2.5 basic dimensions............................................................................................................20
Figure 4.1 forces acting on the main shaft......................................................................................22
Figure 4.2 forces acting on the adjustment shaft.............................................................................25
Figure 4.3 forces acting on the bolts with skeleton view................................................................29
Figure 5.1 metal bending process using oxyacetylene....................................................................40
Figure 5.2 (a) casting process and (b) cutting with power hacksaw...............................................43
Figure 5.3 bending of the handle.....................................................................................................44
Figure 6.1 study result for the main shaft.......................................................................................56
Figure 6.2 study result for the adjustable shaft...............................................................................57
Figure 6.3 study result for aluminum plates....................................................................................57

viii
 List of tables

Table 4.1 standard iso table for bolts..............................................................................................30

Table4.1 model information for main shaft....................................................................................31
Table 4..3 study properties of main shaft........................................................................................32
Table 4.4 material properties of main shaft....................................................................................32
Table 2.5 loads and fixtures............................................................................................................32
Table 4.6 stress and strain value for main shaft..............................................................................33
Table 4.7 model information of adjustable shaft............................................................................34
Table 4.8 Study properties of adjustable shaft...............................................................................34
Table 4.9 material properties of adjustable shaft............................................................................35
Table 4.10 loads and fixtures..........................................................................................................35
Table 4.11 stress and strain value for adjustable shaft....................................................................36
Table 4.12 model information of aluminum plate..........................................................................37
Table 4.13 study properties of aluminum plates............................................................................37
Table 4.14 material property of aluminum plate.............................................................................38
Table 4.15Load and fixtures...........................................................................................................38
Table 4.16 stress and strain value for main shaft............................................................................39
Table 5.1 cost obtained while surveying.........................................................................................46
Table 5.2 indirect machine costs.....................................................................................................51
Table 6.1 result of numerical analysis.............................................................................................54
Table 6.2 simulation result table.....................................................................................................55

ix
 NOTATION

Symbols Descriptions

Fman force exerted

W Weight

F Force

rpm revolution per minute

σb Bending stress
Mb Bending moment

I Moment of inertia

Z Section modulus

𝜏 Torsion shear stress

FOS Factor of safety

L length

E Young’s modulus

do outer diameter

di inner diameter

σmajor major principal stress

σminor minor principal stress
𝜏max maximum shear stress
σt tangential stress
σr radial stress
p density

x
w angular speed
v Poison’s ratio
ri inner radius
ro outer radius
Ptheoretical actual power
Pactual theoretical power

xi
 CHAPTER 1

INTRODUCTION

1.1 Back ground overview

Threshing machines are mechanical devices that separate grain from plant or ear heads. There are
three methods for threshing: rubbing, impact, and stripping. The grain is released and separated
from the stack by threshing. The basic premise of a threshing machine is that it creates an impact
on the crops, separating the grain. Various grains, such as teff, wheat, bean, rice, and others, are
threshed. The following are the main components of a threshing machine:

 Threshing cylinder: - A balanced spinning assembly with a rasp beater bar

or spikes on the periphery and support for threshing the grain.
 Concave: - Metal grating with a concave shape that partially surrounds the
cylinder and rubs the grain from the plant or ear heads against it before
falling on the sieve.
 Cleaning unit: - The purpose of this device is to separate and clean the
threshed grain. The aspirator is made up of two or more oscillating sieves, a
fan, and an air sucking duct.
 Power source unit: uses a pulley belt mechanization to drive the trashing
cylinder and cleaning units.
This components are assembled to make a threshing machine that trashes a crop in an efficient
manner. Threshing was done by hand with flails before such machines were developed; such hand
threshing was exceedingly hard and time-consuming, accounting for around one-quarter of
agricultural work by the 18th century. Farm labor was relieved of a significant amount of
drudgery when this procedure was mechanized. Andrew Meikle, a Scottish engineer, created the
first threshing machine in 1786, and the following adoption of similar devices was one of the
earliest examples of agricultural mechanization. Threshers, mechanical reapers, and reaper-
binders became more common in the 19th century, making grain production much less labor
intensive.

1
 1.2 Statement of the problem
What does engineers do? Engineers look out for solutions, which means there is a problem.
There are lots of problem that hasn’t been solved yet. Engineers are always looking forward to
solve problem and bring simplicity and joy to the rest of the world. In Ethiopia agriculture is the
most promising resource. Agriculture generates 46.3 percent of the nation's GDP, 83.9 percent of
exports, and employs 80 percent of the workforce. [1] Agriculture is important for a variety of
other economic activities, including marketing, processing, and exporting agricultural products.
Agriculture is the mainstay of the economy. But Agricultural development has been hampered by
a number of obvious issues, including irregular weather, environmental degradation, rapid
population increase and shrinking farm sizes, technological gaps, inadequate markets, and
infrastructural issues. Teff is a traditional Ethiopian grain that is used to make injera, which is
eaten by the majority of Ethiopians. It is Ethiopia's most widely used grain, with a wide range of
functions. In practically every agricultural region, the way teff is planted, harvested, and threshed
is still quite traditional, requiring a lot of manpower. Modern agricultural machinery is being
imported into the country these days. However, just a few organizations, tiny agriculture
investors, and a few wealthy farmers use them. The government uses a variety of inventions,
development engineering, and reverse engineering strategies to address the problem in the
agricultural industry. However, due to product inefficiency and lack of in-depth problem analysis,
there is yet to be a big adjustment that will fix the agricultural problem. It has also been
challenging to develop a mechanism that can thresh teff due to its grain characteristics. Teff
trashing machines currently on the market have a number of issues, including being inefficient
and unproductive due to grain loss and incorrect scum removal. So deciding to build a compact
teff threshing machine with proper mechanisms so that other grains can also be threshed for the
sake of being multipurpose and effective in terms of productivity and scum removal. As a result,
the goal of this project is to solve a threshing problem by designing, simulating, and analyzing a
teff threshing machine that is significantly more efficient, reliable, and cost effective.

2
 1.3 Objective

1.3.1 General objective

The main goal of this project is to design, modify, and analysis of a teff threshing machine that
can be used to thresh teff and other grains (particularly teff) in order to boost a country's overall
agricultural productivity.

1.3.2 Specific objectives

Specific objectives of the project are
 To select the best possible mechanism which will give the desired motion.
 To design of teff threshing machine components.
 The selection of material for the machine components
 3D geometry modeling teff threshing machine using solid works V2021.
 Analyze the stress acting on each part using hand calculation and solid works
simulation V2021..

1.4 Study Methodology

Problem Explanation of
Design analysis and
identification and the need for teff
material selection
Data threshing
machine
Collection

No Stress analysis 3D geometry

using simulation preparation using
solidworksV2021 solidworksV2021
Yes
selection

Result and
discussion
3

Figure 1.1 study design

 1.5 Scope of the study
The design, modification, and analysis of a teff threshing machine are covered in this project.
This threshing machine is designed to thresh a variety of cereals in addition to teff, making it
mobile and multifunctional.

1.6 significance of the study

This study paves the road for Ethiopia's agricultural business to grasp the necessary procedures of
designing a teff trashing machine, which will considerably increase the industry productivity.
Second, the project can be updated and tested by creating a prototype. The third benefit is that it
reduces human labor. The fourth benefit is that it maximizes the threshing capacity of the product.
Finally, the study provides insight to other researchers who are engaged on the same field.

1.7 Limitation
Because there haven't been many studies on the teff threshing process, conducting an existing
literature and collecting necessary data has been a considerable drawback.