DESIGN MODIFICATION OF MANUALLY OPERATED GRASS

CUTTING LAWN MOWER MACHINE

BY:

1. DESTA NIGUS 416/10

2. KASSAYE BIZUNEH 766/10
3. ESTIFANOS 509/10

ADVISER: MR. MELKAMU

IN PARTIAL FULFILMENT OF BACHELOR OF SCIENCE DEGREE

WITH MECHANICAL ENGINEERING

ARBA MINCH UNIVERSITY

ARBA MINCH INSTITUTE OF TECHNOLOGY (AMIT)

FACULTY OF MECHANICAL ENGINEERING

 CERTIFICATION

The undersigned certify that they have read and hereby recommend for acceptance
by Arba Minch University a thesis entitled: Design Modification of Manually Operated
Grass Cutting Machine , in fulfilment of the requirements for the bachelor of science
degree in Mechanical Engineering of Arba Minch University.

Advisor:

Name: ………………………

Date: ………………………

Signature……………………

Dean of the Faculty:

Name: Atkilt Mulu (M.Sc.)

Date: ………………………

Signature……………………

i
 DECLARATION

We declare that this thesis is our own original work and that it has not been presented and
will not be presented to any other University for a similar or any other degree award.

1. Name: ………………………………………
Signature……………………………………

2. Name: ………………………………………
Signature……………………………………

3. Name: ………………………………………
Signature…………………………………..

ii
AKNOWELEDGEMENT

iii
ABSTRACT

iv
 TABLE OF CONTENT

Table of Contents
AKNOWELEDGEMENT....................................................................................................iii

ABSTRACT.........................................................................................................................iv

TABLE OF CONTENT.........................................................................................................v

CHAPTER ONE....................................................................................................................7

1. INTRODUCTION.............................................................................................................7

1.1 Background of the Study.............................................................................................7

1.2 Problem Statement.......................................................................................................8

1.3 Objective......................................................................................................................8

1.3.1 General Objective.................................................................................................8

1.3.2 Specific Objective.................................................................................................9

1.4 Significance of the Study.............................................................................................9

1.4.1 Scope of the Project..............................................................................................9

1.4.2. Limitation of the project......................................................................................9

1.5 Organization of the Study..........................................................................................10

CHAPTER TWO.................................................................................................................11

2. LITERATURE REVIEW................................................................................................11

2.1. Two main styles of Blades used in lawn Mowers....................................................11

2.1.1 Rotary mowers....................................................................................................11

2.1.2 Cylinder or reel mower.......................................................................................12

2.2 Comparison of Mowers.............................................................................................12

2.3 Type of mower based on a particular scale and purpose...........................................13

2.2.1. The smallest type...............................................................................................13

2.2.2 The largest type...................................................................................................14

2.3. Lawn Mowers by Energy Source..............................................................................14

2.3.1. Gasoline (petrol)................................................................................................14

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 2.3.2. By Electricity.....................................................................................................15

2.4. Types of Mower Blades............................................................................................17

2.5 Theory of Operation...................................................................................................18

2.6 Technical Definitions.................................................................................................23

2.7 Type of Grass determine how many Blades require to mow................................25

2.8 Human Performance Capability............................................................................26

CHAPTER THREE.............................................................................................................28

3. METHODS AND MATERIALS.....................................................................................28

3.1 Method.......................................................................................................................28

1.4.1 Data Source.........................................................................................................28

3.1 Material Selection......................................................................................................28

3.1 Engineering Materials for Components.....................................................................28

3.3 Components and their Specific Materials..................................................................29

CHAPTER FOUR................................................................................................................32

4.DESIGN AND ANALYSIS.............................................................................................32

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 CHAPTER ONE

1. INTRODUCTION

1.1 Background of the Study

In this pass, cutting of grasses in the school, track or filed, Industries hotel, public centres,
Agriculture lands etc. was done by machete or cutlass. This method of manual cutting not only was
laborious but also time consuming as it is human effort that is entirely needed both for cutting and
motion. There was also inaccuracy in cutting level of the each inaccuracy in cutting level of the
each individual as many factors will influence the late, speed h, height of cut of each individual.

Apart from all these compressional old method of cutting there is also risk of accident. As can one
easily get cut with his or her machete (cutlass). Also there is need for mechanization since the world
is going modernization bearing all these problems in mined trying to find a solution to it; we
decided to embark on this project. This project can be used for cutting of grass. And all the
problems of the manual cutting were meant to be overcome.

Therefore this lawn mower is used for cutting grass to equal length ( though you can adjust to level
of cut) for speed cutting, it is also lies accident fine as well, it has a reduced labour as it is an on.

A lawn mower is an apparatus that has one or more revolving blades to cut grass or other plants of a
lawn at an even height. Lawn mower is an essential tool for the maintenance of yards. They vary in
size, mode of operation, and power. The power source riding mowers for example are usually
powered by a gasoline engine and are ridden and steered by the operator. Walk behind mowers are
designed to be pushed by the operator and typically run on gasoline or electricity. Modern gas
powered and electric powered lawn mowers cut grass with a single blade revolving at a high speed
parallel to the ground.

The blade is slightly raised along its rear edge to create draft that lifts the cutting blades before its
cutting operation. Mulching mowers suspends clippings and other debris near the blade shredding
them before blowing them straight down in the lawn where they serve as manure for future lawn
growth. Okoro, (2010) designed a locally operated engine powered lawn mower. The mower is
fitted with horizontal cutting blade attached to a vertical shaft. The mower was tested and the
average effective field capacity and efficiency were 0.127 2 ha/hr. and 88.4% respectively.
However, all the above mentioned type of mowers are not friendly to the environment, because
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enough carbon monoxide is emitted into the environment, there is much vibration on the part of the
operator, and there is also very serious noise pollution. Jeremy, (2005) designed and fabricated solar
charged lawn mower. The machine was dependent on weather since the battery would be charged
using photovoltaic panel (i.e. solar panel). The common disadvantage was that the engine runs
down easily and the cost of production was high for an average individual to purchase. Victor and
Vern’s, (2003) designed and developed a power operated rotary mower for wet land paddy. The
complex nature of the machine makes its maintenance and operation difficult for the peasant
farmers.

Generally, in areas like ours, the conventional methods of grass cutting involved the use of cutlasses
which never met the maximum satisfaction. More so, it is strenuous, time and labour intensive.
Therefore, there is the need to develop a locally, fabricated spiral lawn mower which can take care
of this operation easily.

Thus this project work aims to reduce labour input in the cutting of not only weeds or grass but also
in the trimming of flowers and trees also it reduces cost, time of cutting and also to beautify the
environment.

1.2 Problem Statement

In general mowing grass is done by cutlasses in almost all over Ethiopia this affects the grass and
the environment. The causes among others include;

 Rapid growth of weeds that affect the grass health and the soil.
 Brings summer drought and maximize the effects of prolonged rainy spells.
 The grass is not return to the soil annually a tenth of its underground bulk in spent
root fibres as humus and, from above, the sum of the year’s cut foliage
 The grass suffers far from such pests like grubs and chinch bugs
 The grass look on its worse health status all year

1.3 Objective

1.3.1 General Objective

The general objective of this project work is design modification of manually operated grass cutting
machine.

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1.3.2 Specific Objective

 To design each part of grass cutting machine

 To select appropriate actuation mechanism for the proposed model.
 To perform part and assemble drawing of each part of grass mower.

1.4 Significance of the Study

The overall health of the grass is enhanced with the regular grass cutting. The life of the grass
improves. The mowing of the grass eliminates the harmful pests from the grass which is again an
important factor for people living on the property.

The well-known benefits of regular grass cutting are:

 Strong Grass
 Uniform Growth
 Mulching
 Super-Fast Recovery Rate
 Clean Yard
 Lush Green Look
 Enhanced Curb Appeal
1.4.1 Scope of the Project

The scope of this project is to design and select main component of grass cutting machine. The
design includes material selection, mechanism design, dimensional analysis, power requirement,
strength analysis, component selection, and 3D model. The machine designed will be based on the
studies conducted by referring to the existing grass cutting machine, And the main scope of this
report is starting from conducting literature review, conceptual designs that fulfil the engineering
design specification, design analysis of the components (design of handle, front axle, big sprocket,
blade, frame etc…) up to conducting manufacturing drawing and modelling of the machine
components.

1.4.2. Limitation of the project

 Limitation of time
 Lack Internet access

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1.5 Organization of the Study

This project work was organized into five chapters. Chapter one: introduces the background of the
study, statement of the problem, objectives, significance, scope and limitations. Chapter two:
discuss extensive literature reviews related to Design of manually operated grass cutting machine.
Chapter three: includes materials that are used to produce parts of grass cutting machine and
methods implemented in this work. Chapter four: discuses about the designed analysis of parts of
grass cutting machine finally, concluding remarks with a recommendation and future research
scopes have been summarized in Chapter five.

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 CHAPTER TWO

2. LITERATURE REVIEW

A lawn mower is a machine that uses one or more revolving blades to cut a lawn to an even height.
The blades may be powered by either by hand by pushing the mower forward, or may have internal
combustion engine to spin their blades some mowers includes other abilities, like mulching or
collecting their clippings.

2.1. Two main styles of Blades used in lawn Mowers

2.1.1 Rotary mowers

Is a mower in which the blade spins horizontally (east to west) and uses a sucking and tearing action
to cut the blades of grass.

Keith Koon [March 24, 2015] A rotary lawn mower is a conventional cutting device that has
horizontal blades mounted beneath the unit in order to trim grass. The unit operates by a gasoline or
electrically powered engine, which propels the sharpened blades in a circular motion around a
centralized pivot shaft.

Figure2. 1Rotary Mower

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2.1.2 Cylinder or reel mower

Edwin beard budding [August 31, 1830] This mower employing a multiple blade assembly that
rotates about a single horizontal axis.

Figure2. 2reel mower

2.2 Comparison of Mowers

Advantages and Disadvantages of a rotary and reel mower

Table2. 1 comparison between rotary and Reel

Rotary Reel

Advantage Powerful Engine Cuts all Cuts lawn evenly Provides a

grass types close cut Clean cutting
method

Disadvantage Tears grass, which could Less powerful Can be tiring

result in discoloration and if cutting a very large lawn
increase risk of disease Not well suited for long
Uneven cut Doesn’t provide grass
a close cut

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Rotary mowers have a horizontal fan-style blade that spins in a circular motion. They also have a
large motor so they can provide enough power to cut thick grass. However, with the horizontal
cutting motion the grass can be torn. When grass is torn rather than cut it can become discoloured
and the frayed ends make it more susceptible to disease. Manually powered reel mowers do not
generate as much power as rotary mowers; therefore they can have a difficult time cutting through
thick grass and weeds. In order to overcome this problem, the mower is designed to increase the
rotational speed of the blade. With the reel mower, the power of the blade reel is directly related to
how much force the user applies. If the operator cannot produce a large enough force, they may
have difficulties operating the mower. The cutting action on a reel mower cuts every individual
blade of grass like a pair of scissors. This produces a clean cut, which will protect the grass from
disease and increases the health of the grass. Table 2 lists the advantages and disadvantages of a gas
and electric mower.

2.3 Type of mower based on a particular scale and purpose

2.2.1. The smallest type

These types are pushed by a human user and are suitable for small residential lawns and gardens.

Figure2. 3 A non-motorized multiple blade reel push mower

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2.2.2 The largest type

Riding mowers are larger than push mowers and are suitable for large lawns .The largest multi-gang
mowers are mounted to tractors and are designed for large expenses of grass such as golf-courses
and municipal parks.

Figure2. 4 The largest mower (Riding)

2.3. Lawn Mowers by Energy Source

2.3.1. Gasoline (petrol)

Figure2. 5 Gasoline of Lawn Mower

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Most rotary push mowers are powered by internal combustion engines. Such engines are usually
four-stroke cycle engines (although a number of older models used two-stroke engines), running on
gasoline (petrol) or other liquid fuels. Internal combustion engines used with lawn mowers normally
have only one cylinder. Power generally ranges from two to seven horsepower (1.5 to 6.75 kW).
The engines are usually carburetted and require a manual pull crank to start them, although electric
starting is offered on some models. Some mowers have a throttle control on the handlebar with
which the operator can adjust the engine speed. Other mowers have a fixed, pre-set engine speed.
Gasoline mowers have the advantages over electric mowers of greater power and distance range.
They do create pollution due to the combustion in the engine, and their engines require periodic
maintenance such as cleaning or replacement of the spark plug and air filter, and changing the
engine oil.

2.3.2. By Electricity

Electric mowers are further subdivided into corded and cordless electric models. Both are relatively
quiet, typically producing less than 75 decibels, while a gasoline lawn mower can be as loud as 95
decibels or more.

Corded electric mowers are limited in range by their trailing power cord, which may limit their use
with lawns extending outward more than 100–150 feet (30–45 m) from the nearest available power
10 outlet. There is the additional hazard with these machines of accidentally mowing over the
power cable, which stops the mower and may put users at risk of receiving a dangerous electric
shock. Installing a residual-current device (GFCI) on the outlet may reduce the shock risk. On the
United States market as of summer 2008, a corded electric mower from a respectable manufacturer
costs about the same as an entry-level internal-combustion mower ($150–200), with significantly
higher reliability, significantly lower cost of ownership, and a significantly reduced carbon
footprint.

Cordless electric mowers are powered by a variable number (typically 1-4) of 12-volt rechargeable
batteries. Typically more batteries mean more run time and/or power. Batteries can be in the interior
of the lawn mower or on the outside. If on the outside the drained batteries can be replaced with
recharged batteries.

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Cordless mowers have the manoeuvrability of a gasoline powered mower and the environmental
friendliness of a corded electric mower, but are more expensive and come in fewer models
(particularly self-propelling) than either.

Comparison of gas vs. electric mowers

Table2. 2 Gas Vs. electric mower

Gas Electric

Advantage Cordless Quiet

Long run time No gas spills

Environmentally

Friendly

Can be cordless

Disadvantage Noisy Limited run time Special

charging equipment
Produces emissions

Gas spills

Requires oil changes

Vibrations

Gas powered lawn mowers have a negative impact on the environment. They produce toxic
emissions, are very noisy and gas spills can occur. By using an electric reel mower instead of a
gasoline powered mower, these problems are eliminated or mitigated. Electric mowers often have
long extension cords that are difficult to use when mowing a large lawn.

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 Figure2. 6 Gas powered mower
2.4. Types of Mower Blades

I. Reel or cylinder blades

Used in reel or cylinder mowers, cylinder blades are composed of three to Seven helical blades
welded in a horizontally rotating cylindrical reel, creating a scissor-like cutting action. Unlike other
types of mower blades, reel/cylinder blades cannot be replaced; therefore, a broken blade requires
replacement of the entire mower. For dull or rusty blades, cleaning and sharpening kits are
available.

II. Deck blades

Also known as the standard or straight mower blade, this is the most commonly used blade on
rotary mowers.

III. Mulching blades

A mulching blade, also known as an all-purpose blade, features a curved surface which allows it to
work in three ways: lifting, mowing, and mulching. First, the blade pulls the grass up and cuts it.
Then, clippings are sucked inside the deck and are chopped into tinier pieces. Finally, the blade's
innermost curve produces air pressure to blow the small clippings out, where they are used to feed
the soil.

IV. Lifting blades

The lifting blade features a slightly curved surface which creates a vertical upward airflow that lifts
the grass up and is assumed to provide a cleaner result than the other types of blades.
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V. Low-lift blade
Low suction power; recommended for mowing terrain with sandy soil.

VI. High-lift blade

Provides the greatest suction power among the three lifting blades, but also requires the most
horsepower. This is the best blade for cutting tall, compact grass.

2.5 Theory of Operation

There are three main structural members in a reel cutting unit: The REEL consists of varying
numbers of helix shaped blades attached to support spiders which are mounted on a rotating shaft.
The BEDKNIFE is attached to the bed bar and the assembly is mounted to the main frame in a
manner that allows for paralleling and adjustment to the reel. The FRAME supports the rollers, the
bed bar assembly and reel with it’s drive mechanism, which can be hydraulic, belt driven or ground
driven. A reel mower cuts grass with a scissors-like shearing action as the moving helix shaped
blades pass over the stationary bed knife. The cutting action requires that the bed knife and reel
blades be sharp, matched, and in close relationship with each other. When properly maintained and
operated, reel mowers provide superior quality of cut. It cannot be overstated that reel mowers

Figure2. 7 Blade and bed knife

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To understand reel cutting theory, you must understand the concept of clip and the shear point. A
shear point is any single point of contact made between the reel blade and bed knife. Clip is the
forward distance travelled between successive blade contacts at one shear point.

Factors Affecting Clip

 The diameter of the reel 13

 The number of reel blades
 The speed of the reel
 The ground speed

By following the blade path through two “clips” as the machine moves forward we can illustrate the
actual process of cutting grass. The bed knife pushes grass toward the shear point while the reel
blade gathers it in front. Each blade path has one-half clip in which to cut all the grass.

Figure2. 8 Shear point of blade

Note that the grass outside of the forward half clip is not easily gathered. The general rule of thumb
concerning height of cut vs. clip is that both measurements should be within 20% of each other. The
best results will be obtained when height of cut is equal to or close to the clip.

Grass extending beyond the forward half clip, yet tall enough to be within the blade path is less
likely to be cut. Reel blades may contact the grass in this area several times prior to the actual
gathering of the grass. This is the so called “fanning” process. This process is more a mechanical
striking of the grass that it is of the commonly thought effect of a blowing action.

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 Figure2. 9 Clip distance
This is an extreme case corrugation. Because of an imbalance between height of cut and clip, the
grass is cut with extreme valleys and peaks.

NOTE: If you change equipment or height of cut you may notice some corrugation after the first
mowing. This will go away after the grass is maintained at the new height of cut over a period of
time. The importance of the bed knife front angle is visible from the side view. Note that the proper
angle allows the grass behind the bed knife front edge to be more effective

A front view illustrates the angle between the bed knife and the reel blade which is called the helix
angle.

Figure2. 10 Angles between blade and bed knife

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Another term known as “the cutting path” is the result of the helix angle and the forward motion of
the cutting unit. The shear point moves down the bed knife as the bed knife moves forward. The
grass is physically cut at an angle to the bed knife.

Figure2. 11 Cutting path

Other factors which affect reel mowing are the grass density and the grass acclimation or grain.
Grass tends to thicken at the normal maintained height of cut. The denser the grass, the easier it is
for the bed knife and reel to gather it. Grass density and grain can often override other factors we
have discussed regarding the cutting action.

Figure2. 12 Cross section of turf cut

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The basic requirements for good performance of reel mowers are:

 The cutting edges on the reel blades and bed knife must be straight and sharp.
 The bed knife must be exactly parallel with the reel.
 The bed knife should be positioned against the reel with light contact.

Factors that affect quality of cut

 Engine governed speed

 Reel bearing condition/adjustment
 Reel and bed knife sharpness
 Bed knife parallel to reel
 Bed knife to reel contact
 Bed knife attitude (angle)

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Table2. 3 Reel and bed knife guarding guideline

2.6 Technical Definitions

Manual reel mowers are simple mechanically. Table 4 displays the important components of a
manual reel type mower.

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Table2. 4 Technical Definitions

Term Description

Handle The handle transfers the user’s input power to the drive
components of the mower.

Rollers Rollers are installed to provide more stability to the structure.

Bed Knife / Cutter Blade Shears the blades of grass acting like scissors with the
assistance from the blade reel.

Blade Reel The second component of the cutting process, aligning the
individual blades of grass with the bed knife.

The shearing between the blade reel and bed knife provides
enough force to cut the grass.

Pinion Gear The pinion gear transfers the power from the rotary motion of
the main wheel to the blade reel.

Main Wheel Main driving component, an internal gear mesh allows the
power to be transmitted to the spinning drum.

Brush Bar The brush bar aligns the grass for optimal cutting.

Axle The axle transfers the power from the pinion gear to the blade
reel.

Adjustment Screws The adjustment screws are used to adjust the height and pith
of the bed knife.

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The location of these components on the reel mower can be seen in Figure

Figure2. 13 Reel mower

2.7 Type of Grass determine how many Blades require to mow

 For bent and heaver grasses (such as Bermuda and St. Augustine)
- Seven blades mower is recommended

Figure2. 14 Type grass

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  For Finer grasses (such as Fescue and Kentucky Bluegrass)
 Four or five blades mower is recommended.(fescue grass has similar properties with the
grasses which are available locally

2.8 Human Performance Capability

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Mower Capacity

The area cut in a given time period. It is commonly expressed in acres per hour. Manufacturers
often publish this information as part of the product specifications. However, because specific
applications ultimately determine the maximum mowing speed, these calculations usually reflect
straight-ahead mowing at an assumed speed with no allowance for overlap, stops, turns, etc. The
following formulas can be used to provide a reasonable base to approximate the acres per hour if
the average ground speed is known or the average speed if the acres per hour are specified.

Acres per hour = inches of cut x speed in mph/100

Speed in mph = acres per hour x 100/inches of cut

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 CHAPTER THREE

3. METHODS AND MATERIALS

3.1 Method

1.4.1 Data Source

Data’s are assessed from different books in the library and internet. The data’s of the materials
which we cannot manufacture locally are also gathered from internet, through direct interview and
observations. In order to design we must consider the following:

 By interviewing concerned body

 By referring different literatures concerning on the grass cutting machine
 Visiting internets
 By conducting conceptual designs
 Selection of suitable and effective grass cutting machine
 Determination of the torque or power required to operate the machine.
 By designing the detail components of the machine such as, shaft, belt, pulley and links etc.
 By using mechanical software like solid work
 Selections of material which will not cracked or affect the grass cutting.
 Development of full specification of the machine
 Detail design calculation based on the specifications

3.1 Material Selection

Selecting materials is a process that is design led in that material selection process uses the design
requirements as the input so as to come up with materials that have the desired properties for the
part to be designed to function well.

3.1 Engineering Materials for Components

The common engineering materials used in making machine components include;

 Stainless steel having AISI No-303

 Annealed steel having AISI No-1020
 Alumnium alloy-5456-HH6
 Steel c-45

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  Carbon steel 40 C 8
 Steel ASTM-A36

Therefore, the right materials for the design of the grass cutter parts should be selected. Selection
requires one to consider the following factors which give the best material to fit for the design job:

A) Specific strength and mass

It is preferable to select a material of high yield stress with ability to carry load without failure.
Therefore, the material selection process should aim to maximize the quantity termed as the specific
strength.

B) Resistance to abrassive wear

Most of engineering materials in contact with one another are subjected to surface wear due to
relative motion. It is therefore desirable to select a material from the candidate materials with low
wear rate or capacity to resist abrasive wear.

C) Availability,Cost and affordability

It is also preferable to choose a material with the highest affordability rating. Relative cost of the
materials is used in finding or calculating the affordable rates. Therefore, the availability of the
material and the cost of processing the material into the finished product need to be taken into
account and considered as supporting information when making the final choice of the material.

3.3 Components and their Specific Materials

The goal of material selection is to come up with an appropriate material that best meets the design
requirements. The approach is to identify the connection between functional requirements and the

material properties we want to get for the design.

The following are components and materials required in the design of a grass cutter (lawn mower).

1. Handle

A36 is a low carbon steel. Low carbon steels are classified by having less than 0.3% carbon by
weight. This allows A36 steel to be easily machined, welded, and formed, making it extremely
useful as general-purpose steel.

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2. Rear axle

AISI 1020 has low hardenability properties and is a low tensile carbon steel with a Brunel hardness
of 119 – 235, and a tensile strength of 410-790 MPa. It has high machinability, high strength, high
ductility and good weld ability. It is normally used in turned and polished or a cold drawn
condition.

3. Rear wheel

It has three components; - hub, arm and rim

Hub –we selected annealed steel b/c it’s a comparable material that reduces wear of parts due to
hardness difference and it has high machinability, high strength, high ductility and good weld
ability. It is normally used in turned and polished or a cold drawn condition.

Arm and rim – they have good tensile and medium strength, suitable for shafts.

4. Chain drive

C45 grade steel is medium carbon steel offering moderate tensile strengths. The material is capable
of through hardening by quenching and tempering on limited sections but can also be flame or
induction hardened to Hrc 55.

5. Shaft

Steel St.37 is a widely used metal in industry. Lightweight, corrosion resistant, and good heat
conductor cause aluminium is selected to be one of the materials to make a machine component
such as alloy wheels, pistons, and other machine components.

6. Cutting blade

Medium- carbon steel at best. So from a lawnmower blade you can make a knife that will act like a
lawnmower blade- it will bend instead of breaking and smooth instead of chipping.

7. Frame

Aluminium frames offer an impressive balance of strength, stiffness and low weight; aluminium
alloys can be prone to long-term fatigue, unlike steel and titanium. However, aluminium frames
tend to be less susceptible to crash or accidental damage than carbon frames.

30
8. Front axle

AISI 1020 has low hardenability properties and is a low tensile carbon steel with a Brunel hardness
of 119 – 235, and a tensile strength of 410-790 MPa. It has high machinability, high strength, high
ductility and good weld ability. It is normally used in turned and polished or a cold drawn
condition.

9. Wheel bracket

AISI 303 is an austenitic stainless steel, offering an excellent machinability and toughness, being
the most readily machine-able of all austenitic grades of Stainless Steel. It's corrosion resistance
however.

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 CHAPTER FOUR

4. DESIGN AND ANALYSIS

4.1 Force Analysis

Considering most of the time male are engaged with mowing process and let’s take 𝑃95 of
population percentile for male

Push out force= 412N

SO, standing from this data 𝐹𝑛𝑒𝑡 = 𝐹𝑐𝑜𝑠𝜃 …………eqn. (4.1)
(412*1.2)N*cos45 =349.6N
𝐹𝑑 = 𝐹 ∗ 𝑠𝑖𝑛𝜃= 494.4N*sin45 = 247.2N …………eqn. (4.1.1)
𝑊 = 𝐹 ∗ 𝑑 ∗ 𝑐𝑜𝑠𝜃 …………….eqn. (4.1.2)
Table 4.1 time measurement of mower travel

Time measurements for 6 meters of mower travel

Measurement Time (s)
1 4.85
2 4.50
3 4.33
4 4.70
5 4.60
6 4.54
7 4.62
8 4.59
9 5.03
10 4.80
Tavg= 4.68

Typical operator walking speed was determined using the average time to walk 6 meters with
the Following calculation.

Dwheel=0.25 m
Vwalk=1.23m/s

Cwheel= π *Dwheel=3.14*0.25=0.785
Wwheel=Vwheel/Cwheel=1.23/0.785=94 rpm ………………eqn.(4.1.3)

32
Hence its design needs critical attention. We chose plate type metering device. The material is
chosen to be mild steel metal.
The diameter of the wheel is 0.25m.The maximum diameter of the spider plate is 0.18m in
diameter and speed of the mower is 1.23 m/s. When the wheel rotates once the blade rotates six
times.

4.2 Power Requirement

The power required to drive the machine can be obtained from equation 12 as given by Okoro
(2010). Power to overcome inertia in pulling machine to motion

Poi =m x g xVo ………eqn. (4.2)

=20kg*9.81m/s2 *1.23m/s=241.326W

ii Power to overcome grass cutting resistance

Pct = Fct x Rb xWb ……………eqn. (4.2.1)
=11.21*0.1*700 rpm=784W
Total power = Poi + Pct =241.326W+784W=1025.326W= 1.025KW
4.3 Design of Handle

Figure4. 1 Handle

33
Average height of human is 165cm. standing from the given information, take the overall height of
the handle 160cm and inclined 45 ° so any operator above or below 160cm can operate
comfortably.

Effect of Angle of Mower Handle on Manoeuvrability

Fig. 4.2 shows the effect of handle angle on manoeuvrability of the mower. Force required to move
the mower, P = W sinθ (Yong and Chow, 1991)

Figure4. 2 Handle angle

Below 40 degrees the mower handle becomes very uncomfortable to handle and pushing the mower
becomes quite difficult. At an angle of 45 degrees, the handle is found most convenient in terms of
freedom in moving the mower.

Material selection
Table 4.2 Handle Material Selection

Density Material Su (Mpa) Sy (Mpa)

7860 Steel (ASTM-A36) 400 145

Section Area of Distance Moment Section Radius

34
 Section from neutral Inertia, I Modulus Gyration
axis to Z=I̸y R=
1/ 2
extreme (I ̸ A)
fibre, y
Πd 2 πd
2
πd
3
d̸2
¿ ¿
4 d̸2 64 32
= 0.049d 2 = 0.098𝑑³

 Part 1

Figure 4.3 Upper Part of Handle

Human push force=412N*1.2= 494.4𝑁

Assuming push force distributed into right and left hand equally
F1=F/2, F2=F/2 F1=2472N, F2=247.2N
Section a-a

∑ 𝐹𝑦 = 0 ……………eqn.(4.3.2)

35
𝐹1 = 𝑉 = 247.2𝑁
∑ 𝑀𝑎 = 0 ………….eqn.(4.3.3)
𝑀@𝑥 = 0, M= 247.2𝑁 ∗ 0 =0
𝑀@𝑥 = 150 , 𝑀𝑎 = 247.2𝑁 ∗ 150 = 37080𝑁 − mm
Section b-b

494.4N
∑𝐹𝑦 = 0
247.2𝑁 + 𝑉 = 494.4 𝑁
𝑉 = 247.2𝑁
∑𝑀𝑏 = 0
𝑀𝑏 = 494.4(𝑋 − 150) + 247.2X ,@𝑥 = 150𝑚𝑚 494.4(−150)
𝑀𝑏 = 37080𝑁𝑚𝑚
𝑀𝑏 = 494.4(300− 150) − 247.2𝑁 ∗ 300
𝑀𝑏@𝑥 = 𝐿
𝑀𝑏 = 0

 Part 2

36
 Figure4. 3 Middle Part of Handle
𝜎𝑐 = 𝑝 ̸𝐴 …………..eqn.(4.3)
𝐴 = 2𝜋𝑟ℎ = 2 ∗ 𝜋 ∗ 15𝑚𝑚 ∗ 1000𝑚𝑚 = 94,247.78m𝑚² = 0.094𝑚²
𝜎𝑐 = 247.2𝑁/0.094𝑚² = 2629.8𝑁/m
𝜎𝑚𝑎𝑥 = 𝑃 ̸𝐴 …….eqn.(4.3.6)
247.2 N
¿ 2629.8 kN /m²
0.094 m ²
400 ∗ 10³𝑘𝑝𝑎 > 2629.8𝑘𝑝a
So it is safe!!
 Part 3

Figure4. 4 The lower horizontal part of handle

For Section a-a

∑ 𝐹𝑦 = 0, 123.6𝑁 = 𝑉

37
 ∑𝑀𝑎 = 0
𝑀𝑎 = 123.6𝑁 ∗ , 𝑀𝑎@𝑥 = 0 , 𝑀𝑎 = 0
𝑀𝑎@𝑥 = 365𝑚𝑚
123.6𝑁 ∗ 365𝑚𝑚 = 45114𝑁 – 𝑚m
For section b-b
247.2N

123.6N
∑𝐹𝑦 = 0
123.6𝑁 = 247.2𝑁 + 𝑉
𝑉 = 123.6𝑁
∑𝑀𝑏 = 0
−𝑀𝑏 − 123.6 ∗ 𝑥 + 247.2 ∗ (𝑥 − 365) = 0
𝑀𝑏 = 123.6𝑥 + 247.2𝑥 − 90228
𝑀𝑏@𝑥 = 365, 𝑀𝑏 = 45114𝑁𝑚𝑚 𝑀𝑏@𝑥 = 730 , 𝑀𝑏 = 0

 Part 4

Figure4. 5 The lower vertical part of handle

𝜎𝑐 = 𝑃 ̸𝐴 ………………eqn.(4.3.1)

38
 123.6 N
= 1314.9KPa
0.094 m 2
𝜎𝑡𝑢 ≥ 𝜎𝑐, 400𝑀𝑝𝑎 > 1.314𝑀𝑝a
So the design is safe!!!
𝜎𝑚𝑎𝑥 = 𝑃/𝐴
123.6 N
2
π∗0.03 ̸ 4
400𝑀𝑝𝑎 > 174𝑀𝑝a ,So the design is safe!!

4.4 Design of Rear axle

Figure4. 6 Rear axle

Since the axle is supported and attached on the wheels by pin, bolt or another means so, it is
considered as a simply supported beam (A beam supported or resting freely on the supports at its
both ends). The materials selected for the axle have higher bending and shearing strength.
Basically, materials used for axle/shaft should have the following core properties:

 It should have high strength: therefore to with stand forces applied on it.

 It should have good machinability: for the easy of manufacturing.

 Good heat treatment properties: This provides the shaft with good surface properties
that can resist failures due to fatigue, wear and creep.

 It should have good wear resistance properties especially when there is a necessity to
use the axle with journal bearings and similar parts

We have selected a steel (annealed) having AISI number 1020 with σt = 394.7Mpa and σy =
294.8Mpa, L=790mm, F.s =2.5

The total weight applied on the axle is load from the handle, and supporting frame. The support
forces of the wheel are, R1 and R2;
39
Therefore the load on the sprocket is due to tangential force, Ft=729.715N =Fc

FA=FAx , FBx=FB , FC=Fcx

The bending moment on the shaft becomes maximum when the shaft (axle) carries all the loads in
the same direction. The material used for the handle and shaft should resist maximum design
load.so using service or design factor of 1.2.maximum load to withstand is 412*1.2=494.4N.

Since the handle is located is located at an angel of 45 degree, it should have to be t decomposed in
to y-direction and x-direction,

Sin 45=Fy/FA, Fy=sin45*247.2=174.76N. Fy=Fx ………….eqn.(4.4)

∑Fx=0, FHA + FHB+ Fcx= R1+R2

40
 R1+R2=1224.115N
Taking moment at A, ∑M=0, Cx*0.06+FB*0.79-R2=0
R2=239.06N. From equilibrium R1+R2=1224.11N
R1=985.05N
Section A-B

FHA+V1-R1=0, V1=711.8N.
M1-R1*x+FHA*x=0 ,
M1=(R1-FHA)*x M@x=0=0 and M@x=0.79=583N.

And, M MAX = 𝐹𝐿/4

= 4882.2N (the maximum moment is at the end of the shaft)

Considering the deflection or bending:
σy 294.8
σb= S . F = 2.5 =117.9Mpa

(σb ) This is the allowable bending stress;

Mmax πd 3
σb = Where, Z =
z 32

Then, for circular cross section we have,

( 4882.2 ) (32)
117.9Mpa = 3
(π d )

d =45mm

41
Considering shear stress:
The shear stress is applied at the wheel positions and it is due to the shear force of 174N.
Fs
τ= …………………eqn.(4.4.1)
As
Where, Fs - shear force applied

As −Shear area

F s ×4 (174)( 4)
τ= 2 = = 0.109 Mpa
πd π 452

Therefore, the shear stress applied on the axle is less than the allowable stress. So, the above
diameter is safe.

4.5 Bearing Selection

Figure4. 7 Bearing
The bearings type selected is rolling contact bearing, perhaps there are other types of bearings but
rolling contact has preferable to grass mowers. Some advantages of rolling contact bearings are;

 Ability to with stand momentary shock loads.

 Accuracy of shaft alignment.
 Low cost of maintenance, as no lubrication is required while in service.
 Small over all dimensions.
42
  Reliability of service.
 Easy to mount and erect.
There are also types of rolling contact bearings, we select ball bearings. There are also two types
of ball bearings, these are;

- Radial ball bearings

- Thrust ball bearings
We select radial ball bearings, because it is more advantageous to the machine than thrust ball
bearings.
- From principal dimensions for radial bearings, the selected ball bearing dimension
is: So, the bearing number selected is 208 with the given parameters,
Din = 45mm Douter = 55mm t = 10 mm

4.6 Design of rear wheel

Figure4. 8 Rear wheel

The wheel going to be designed is the one fixed on the axle for a required dimension. It rotates with
the axle at a translational speed of 0.5m/s and rotational speed of 20rpm. The diameter is assumed
to be 400mm. This diameter is taken to match furrow height and the metering disc extension down
the axle. The surface of the rim is no smooth, which are used to avoid friction on wet condition.
Now, let us proceed to the design of different parts of the wheel. Assum Ft = 412.7N, Fc= 0.725N
from the material selection

43
1. Wheel Hub
The wheel hub is the one which have direct contact with the axle. It is fixed with the axle using nail
through hole provided both in the hub and the axle.
Material of the hub
Since we have chosen annealed steel for the axle, we should choose a comparable material for the
hub too. This is to reduce wear of parts due to hardness difference. Therefore, we choose the same
material for the axle.
Shear stress = Fs / As ………eqn.(4.5)
Where, shear stress = 0.5 σy/SF…………eqn.(4.5.1)
= 58.9MPa
The resultant force applied is calculated to be 412N And we have,
A s = (L) (t) ………….eqn.(4.5.2)
We can assume, L = 100mm, t = 30 As = 3000mm²
Since it is in direct contact with the axle it tends to be crushed.
1. due to the vertical weight
2. due to the traction force
The more critical is crushing due to the traction force. This force is divided equally into the two
wheels. We have
Fc= 0.725N
πdl
Ac = 2 = 15700mm 2

Therefore, σc= FC /AC = 0.000461Mpa

44
This value is very less than the allowable shear stress. So, it is safe for crushing. Design for tearing:
Ft
𝜎𝑡 = ………eqn.(4.5.3)
At
Ac
Ft = 412N and, At = =7850mm²
2
Therefore, 𝜎𝑡 = 0.0524 Mpa so, the hub is safe for tearing.
Generally, the hub with such a material is safe enough. Strength is not critical here. But to meet
other requirements we may change the hub thickness and length as required. As checked in the
previous analysis
Design of Arms
Arms of the wheel are subjected to variable loading. The main stresses are:
1. Compressive stress when arms are in the lower half of the wheel
2. Tensile stress when arms are in the upper part of the wheel
3. Bending stress due to the tangential force developed at the circumference of the wheel.
Design of the arm’s length
In the preceding analysis the wheel diameter has been assumed to be 400mm. So, subtracting the
outer hub diameter from the wheel diameter, the length of the arm will be, 100mm –
400mm+400mm = 100mm
The total number of arms for a wheel with a diameter of 100mm is 4. At the circumference of the
hub the number of arms that can be chosen to be four.
Design for buckling:
Assuming the arm as column and given l=400mm, E= 207GPa, G= 79.3 GPa ,  0.292
The above properties are for carbon steel.
Preceding to the calculation
The centre of gravity is the centre of cross-section, since it is circular.
4
πD
I= ……eqn.(4.6)
64
Taking the diameter to be 20mm I= 7850mm2 Moreover, the column is fixed at both ends.
Therefore, equivalent length L = l/2 = 200mm the creeping load
4
EI π
Wcr = 2 ……….eqn.(4.6.1)
L

45
 4
207∗0.07850 π
Wcr = 2 = 0.0394GPa
200
This means
Design for bending: From free body diagram of the arm (Dimension is in mm) considering it as a
cantilever beam
M
b  Z ……eqn.(4.6.2)

The maximum bending moment

Mmax = F × L max  494.4*100mm = 49440Nmm
Z = section modulus
4
πD
Z= =15.7mm³
32
M 49440
b  Z = 15.7 = 3149.04 N /mm 2

Design of the Rim

The rim of the wheel critically subjected to three main stresses: tearing, shearing, bending stress at
the rim part between consecutive arms ends.
Assumptions:
For shearing it is assumed only parts of the rim with area equals to the projection of the end of the
arm end is subject. In case of tearing it is assumed that only the part between two arms is assumed
to be subject to. The bending is critical when the part of the rim at the middle of two consecutive
arms is in contact to the ground. L =400mm, t= w =30

4.7 Design of Chain Drive

Figure4. 9 Chain drive

46
Chain drive is made up of number of rigid links which are hinged together by pin joints in order to
provide the necessary flexibility for wrapping round the driving and driven wheels. The chains are
mostly used to transmit motion from one shaft to another, when the centre distance between their
shafts is short. These wheels have projecting tooth of special profile and fit into the corresponding
recesses in the links of the chain. The toothed wheels are known as sprocket wheels.

Advantages and Disadvantages of Chain Drive over Belt or Rope Drive

Advantages
 As no slip takes place during chain drive, hence perfect velocity ratio is obtained.
 Since the chains are made of metal, therefore they occupy less space in width than a belt or
rope drive.
 It may be used for both long as well as short distances.
 It gives high transmission efficiency (up to 98 percent).
 It gives fewer loads on the shafts.
 It has the ability to transmit motion to several shafts by one chain only.
 It transmits more power than belts.
 It permits high speed ratio of 8 to 10 in one step.
 It can be operated under adverse temperature and atmospheric conditions.

Disadvantages
 The production cost of chains is relatively high.
 The chain drive needs accurate mounting and careful maintenance, particularly
lubrication and slack adjustment.
 The chain drive has velocity fluctuations especially when unduly stretched.
 Under taking the consideration of less load on the shaft, transmit more power and high
transmission efficiency, the disadvantage is t h a n the advantage.
Material selection: Steel, C-45 σy= 360 MPa σut= (630-710) MPa E = 210 Gaps

47
 N1 T 2
The velocity ratio of the chain drive is given by; V.R = =
N2 T1
Where, V.R – velocity ratio of chain
N1 – speed of rotation of smaller sprocket in rpm
N2 – speed of rotation of larger sprocket in rpm
T1 – number of teeth on the smaller sprocket
T2 – number of teeth on the larger sprocket
πDN TpN
The average velocity of the chain is given by, v = =
60 60
Where, D = Pitch circle diameter of the sprocket in metres, and
p = Pitch of the chain in metres
Given: P = 1480 watt
N1 = 540rpm (700rpm, from table 4.4)
Table 4.4 Power rating (in kW) of simple roller chain.

N2 = 94rpm N1 = 540rpm
48
Analysis: the velocity ratio, V.R will be
V.R = N2/N1 ………..eqn.(4.7.1)
= 540/94 =5.75~6
From the table 4.5, V.R the minimum number of teeth in one sprocket is 17.
V.R= N1 ̸ N2 = T2/T1
V.R = TPN/60
T2
6= , then T2 = 102
17

Table 4.5 Number of teeth on the smaller sprocket

This means number of teeth on the sprocket is 17. Design power = (rated power) (service factor)
The service factor (ks) is the product of various factors k1, K2 and k3. The values of these factors
are taken as follows:
Load factor (k1) = for constant load = 1
Lubrication factor (k2) = for periodical lubrication = 1.5
Rating factor (k3) = for 8 hours per day is 1
So that, service factor will be
Ks = (k1) (k2) (k3) = 1.5
Design factor = (rated power) (service factor)
Design factor = (1480) (1.5) = 2220Watt

Choosing the Type of Chain

In order to strength, less noise, simple construction and gives good service under sever condition
Bush Roller Chain is selected. This chain also may be used a little lubrication. Bush roller chain as
shown in fig.4.11 consists of outer plate or pin link plates, inner plates or roller link plate’s pins,
bushes and rollers. Pin passes through the bush which is secured in the hole of roller between the
two sides of the chain. The rollers are free to rotate on the bush which protects wheel teeth against
wear. The pins, bushes and rollers are made of alloy steel.
49
 Figure4. 10 Bush roller chain
The roller chains are standardized and manufactured on the basis of pitch. These chains are
available in single-row or multiple-row roller chains such as simplex, duplex and triplex strands.
Considering cost and les power the simplex chain is selected.
Table 4.6 Characteristics of roller chains according to IS: 2403 — 1991

Now from standard size of pitch (I.e. pitch = 9.525mm) of the tricycle simply we can determine the
following characteristics of roller chain according to are: 2403 – 1991.
Chain number = 06B Pitch of the chain,
p = 9.525mm Roller diameter,
d1 = 6.35mm Minimum width of roller,
50
W or b1 =5.72mm Breaking load,
WB = 8.9KN
Table 4.7 Power rating (in kW) of simple roller chain

The pitch circle diameter and pitch line velocity of the smaller sprocket (pinion)
D1 = pcosec (180/T1)
= (9.525) cosec (180/17) = 0.0518m
Pitch line velocity of the sprocket
V = πDN/60 = π (0.0518) (700)/60, from table 4.7(Gupta) N=700 rpm.
= 1.8976m/s
Ft for the smaller sprocket wills be, Ft=p/v=779.93N=0.779KN.
Load on the chain (W), W = rated power/pitch line velocity = (1480)/1.8976=779.8
=0.779KN
Factor of safety = WB/W = 8.9/0.779,
Where WB=106P2 (breaking load for roller chain) =11.42
This value is more than the value given in table which is 8.9, so the chain is quite safe.
πDN π∗0.0518∗94
Velocity of the chain is given by, V = = =0.255 m/s.
60 60
The total load (or total tension) on the deriving side of the chain is the sum of the tangential driving
force (Ft) ,centrifugal tension in the chain(Fc) and the tension in the chain due to sagging (Fs).
P
Ft= where, P=power transmitted V=speed of the chain
V

51
 wb∗V 8900∗O .255 605.2
P=WB*V/n*ks = =605.2W, Ft= =2373.33 N=2.373kN.
n∗KS 2.5∗1.5 0.255

4.8 The Cutting Blades

The cutting blades are chosen as they appear in the spiral blade (helical blade) lawn mower. The
blades are in two sets, the bed-knife and the reel. The reel is made up of five smaller blades (since
fescue grass is dominant in Ethiopia) of sizes 680mm x 25mm x 2mm and is made of steel
materials. The blades are mounted on the five spiders rigidly fixed to the shaft and are oriented at a
helical angle of 120 to the horizontal on the circular spiders for efficient grass cutting. The bed knife
is also made of steel material of size 680mm x 60mm x 2.6mm. Both edges grinded with a front
relief angle of 300 to make grass cutting easy in a scissor action with the reel. The bed-knife is fixed
to the machine frame behind the reel.
The force required by the cutting blades to shear the grass is given by;
F=T/R ……eqn. (4.8.1.1)
R= 10cm
Speed of blade and shaft=700 rpm
Power transmitted=1480W
P × 60
T= ……eqn.(4.8.1.2)
2 πN
1480× 60 T 1.121
T= = 1.121Nm But T=F*r; F= = =11.21N.
2 π 700 r 0.1

Where the parameters are; d = 200mm, P = 11.21N

2 2
πd π 200
Area, A = = = 31400mm 2
4 4
( disc radius−shaft radius )+(s haft radius)
Radius of curvature for the disc is, R =
2
52
 ( 10−2.5 )+(2.5)
R= = 62.5mm
2
2 4
d d
The factor (h2 ) for the circular disc is; h2 = ( ¿ +( 2
¿
16 128 R
h 2 = 834

To know the number of helical blade to be attached on the spider disc (reel blade disc) is with
respect to the clearance. Circumference of the disc is, C = 2𝜋𝑟 = 2(10𝑐𝑚)= 62.8cm,for the specified
grass type the number of blade is 5.

4.8.2 Shaft design

A shaft is component of mechanical device that transmits rotational motion and power. It is integral
to any mechanical system in which power is transmitted from a prime mover, such as an electric
motor or an engine to other parts. Visualize the forces, torques and bending moments that are
created in the shaft during operation. In the process of transmitting power at a given rotational
speed, it is inherently subjected to a Torsional moment or torque. Thus, Torsional shear stress is
developed in the shaft.

Material selection; St-37 with, F.S =2.5

𝜎y=220Mpa, 𝜎u=360Mpa, 𝜏y=105Mpa, τ = 341Mpa, τ ult 𝜌=1730kg/m3,

P=0.815hp or 608.11W (1480w or1.98hp) Le=850 mm, and N=540 rpm (700rpm gupta table 21.4)

And the material used for shaft has the following criteria;
 Shaft length should be kept as short as possible.
 It should have high strength.
 It should have good machinability.
 It should have good heat treatment property.
 It should have high wear resistance property.

53
 Figure4. 11 Cutting blade and shaft
Considering z-y axis

Where, Le – effective length of shaft=850mm

P – Power of the man (manual input which is the human pushing force and average walking speed
input) =608.11 watt=0.815 hp but take 1.98hp from the standard.
Assumption: mass of single spider plate= 600g=0.6kg
Mass of single reel helix blade =500g.
Single weight on the shaft will be, W=(0.5kg + 0.6kg)*9.81m/s2=10.79N.
Therefore, the Total weight on the shaft is; W = 10.79N*5= 53.95N
∑𝐹𝑦 = 0, Ay + By=WT ……..eqn.(4.8.2.1)
Ay + By=53.975N
Taking moment at A;
By (85) = [(W) (17) + (W) (32) + (W) (47) + (W) (62) + (W) (77)]
By = 29.83N
From equilibrium equation we have, Ay = (53.975) – (By) = 24.14N
To draw SF and BMD 0F the haft, follow the procedure below,

54
∑M=0 ……eqn.(4.8.2.2) , M1-27.92*X=0, M1=27.92x

M1@x=0,=0 and M1@x=0.08,=2.23Nm.

V1=27.92N

∑𝑀 =0, M2-27.92*X+10.791(X-0.08)
M2=17.13*X+0.86
M2@x=0.08,=2.23Nm.
M2@x= 0.23,=6.42Nm.
∑F =0
V2+w=Ay
V2+10.79=27.92, v2= 17.13

∑𝑀 = 0, M3-27.92*X + 10.791(X-0.23)=0
M3@x=0.23 =6.42Nm, M3@x=0.38,= 10.61Nm.
V3 +W1+W2=Ay
V3=27.92-21.56= 6.36N

55
∑𝑀=0, M4-27.92X+10.79(X-0.38)

M4@x=0.38, =10.61Nm, M4@x=0.53,=14.80Nm.

V4=-4.45N

∑𝑀=0, M4-27.92X+10.79(X-0.53)

M5@x=0.53, =14.80Nm

M5@x=0.68=19.0Nm, V5 = W1+W2+W3+W4-Ay
= -15.37

∑𝑀=0, M6-27.92X + 10.75(X-0.68)

56
M6@x=0.68 =19.0Nm, and M7@x=0.0.17 =23.73Nm

4.9 Design of key

Key is a piece of mild steel inserted between the shaft and hub or boss of the gear or between the
shaft and rotating disc in order to connect these together for the purpose of preventing relative
motion between them. Keys used as temporary fastening and are subjected to considerable crushing
and shearing stress.

From the different types of keys, I select sunken key with rectangular cross-section due to:
 Easy to manufacture.
 Appropriately assembles to the internal part of gear or shaft. Or it is easy to assemble
spur gear with the shaft.

Figure 4.13 rectangular sunk key

This key is used to attach the sprockets with shaft and axle. Material selection: steel, C-45 with 𝜎y
= 360N/mm2 and 𝜎u= (630-710) N/mm2
Assumption: - type of key is square sunk key
- Factor of safety = 4
Diameter of the shaft is, d= 50mm
Analysis: dimensions of key:
d 50
Since, it is square key, w = t =
4
= 4 = 12.5mm
In order to find the length of key, let’s see the two failures applied on key.
The failure of key due to shearing

57
τ = 2T/L×w×d T = π/16 × d 3 × τ 1 Where τ = shear strength of the key material
τ 1 = shear strength of the shaft material
Therefore
L = πd 2/8w = π202/8×5 = 31.5mm
The failure of key due to crushing
σ c = 4T/L*t*d …………… T = π/16 × d 3 × τ 1

L = πd 2 τ 1/4 σ c t = π202 ×40/4×90×5 = 28mm

Taking the larger of the two values, we have L = 31.5mm, say 32mm
 Checking the shear strength of the key against the normal strength of the shaft Strength of
the shaft with key way
T 1 = π/16 × d 3 × τ × e
Where e = shaft strength factor e= 1 – 0.2(5/20) – 1.1(5/2×20) = 0.8125
Therefore T 1 = π/16 ×20 3 × 45 ×0.8125 = 57.43kN
Shear strength of the key
T 2= L×w×τ×d/2 T 2= 32×5×45×20/2 = 72kN
Therefore, Shear strength of the key/Normal strength of the key = 72/57.43 = 1.25
Therefore, the key is quite safe.

4.10 Design of frame

Aluminium frames offer an impressive balance of strength, stiffness and low weight, aluminium
alloys can be prone to long-term fatigue, unlike steel and titanium. However, aluminium frames
tend to be less susceptible to crash or accidental damage than carbon frames.

Figure 4.14 frame

Table 4.9
58
 material Ultimate strength Yield strength Density

(Mpa) (Mpa) Kg/m³

Aluminum 315 130 2630

Alloy-5456-H116
Assuming the support as a beam

W1 and w2 are the front and the rear axle distributed force.
𝐹1 = 𝑤1 ∗ 4𝑐𝑚, F2=w2*2c
F1=60.76N +213.4N =274.16N

F2=213.4N
W1=wt(blade) + Ft , Wt blade= 60.76N , Ft = 213.4

∑ 𝐹𝑦 = 0, 𝑅1 + 𝑅2 = 𝐹1 + 𝐹2=25N
∑𝑀𝑜 = 0
−𝐹1 ∗ 207𝑚𝑚 − 𝐹2 ∗ 441𝑚𝑚 + 𝑅2 ∗ 500𝑚𝑚 = 0
274.16𝑁 ∗ 207𝑚𝑚 + 213.4𝑁 ∗ 441𝑚𝑚 = 500𝑅2
𝑅2 = 301.72𝑁
𝑅1 = (𝐹1+ 𝐹2) − 𝑅2
𝑅1 = 185.84N

59
Section a-a

∑ 𝐹𝑦 = 0
𝑅1 = 𝑣1 = 185.84𝑁
𝑅1𝑥 = 𝑀𝑎, 𝑀@𝑥 = 0
𝑀@𝑥 = 207𝑚𝑚
𝑀𝑎 = 301.72 ∗ 207𝑚𝑚 = 38460𝑁 – 𝑚m

Section b-b

∑ 𝐹𝑦 = 0, 𝑅1 + 𝑣2 = 𝐹1
274.16𝑁 − 185.84𝑁 = 88.32𝑁
∑ 𝑀𝑏 = 0, −𝑅1𝑥 + 𝐹1(𝑥 −207mm)=0
R1x-F1x+F1207=Mb
𝑀@𝑥 = 207𝑚𝑚
𝑀𝑎 = 38468.88𝑁 − 𝑚𝑚
𝑀@𝑥 = 441𝑚𝑚
185.84𝑁 ∗ 441 − 274.16 ∗ 441 + 274.16 ∗ 207 = 𝑀𝑏
𝑀𝑏 = 81955.44𝑁 – 𝑚m
60
Section c-c

∑𝐹𝑦 = 0
185.84𝑁 + 𝑣 = 274.16𝑁 + 213.4𝑁
𝑣 = 2.6𝑁
∑𝑀𝑐 = 0
−𝑅1𝑥 + 𝐹1(𝑥 − 270) + 𝐹2(𝑥 + (441)) − 𝑀𝑐 = 0
𝑀@𝑥 = 441
𝑀𝑐 = 81955.44𝑁 − 𝑚𝑚
𝑀@𝑥 = 𝐿 = 170946.2𝑁 – 𝑚m
Mc
𝜎𝑏 =
I
= (170946.2 ∗ 15)/79380=32Mpa
Sy 130
𝜎𝑎𝑙𝑙 =
2
= 2 = 65𝑀𝑝a
𝜎𝑎𝑙𝑙 > 𝜎 ,so the design is safe!
Shear stress in the circle due to tear out
Ss=F/(do-d)b
274.16N/(90-50)*30 = 0.228𝑁 𝑤ℎ𝑒n 𝑖𝑠 𝑠𝑜 𝑠𝑚𝑎𝑙𝑙 𝑓𝑜𝑟 𝑡𝑒𝑎𝑟 out

4.11 design of bolt

Material selection
Table 4.10
E (Gpa) G (Gpa)
𝜌(kKg/m3) 𝛿𝑦(𝑀pa) 𝛿𝑢(Mpa)
207 79 7.7 230 370

δy 230
c. Analysis: - using the maximum shear stress theory: 𝜏 all =
2
= 2
=115Mpa

61
 Fs
𝜏=
As
4 Fs
𝜏𝑎𝑙𝑙 = 2 , where 𝐹𝑠 = 494𝑁 𝑓𝑜𝑟 𝑏𝑜𝑡ℎ 𝑏𝑜𝑙𝑡s
πd o
4∗494
115𝑀𝑝𝑎 = 2 = d o 2 = = 4 ∗ 494𝑁/(115𝑀𝑝𝑎 ∗ 𝜋)
πd o
do = 5
From standard bolt diameter let’s take do=10mm,

Table 4.11
Designation Pitch d=D dp dc (bolt) dc(nut) depth of
thread (mm)

M10 1.5 10.000 9.026 8.160 8.876 0.920 58.3

Also, we can know height of the bolt having,

dc= 8.160mm h= 2(8.160) + t = 2(5) + 80 = 90mm
2
Fs d
𝜏= = 25𝑀𝑝a , 𝐴𝑠 = 𝜋 ∗ = 19.6𝑚𝑚²
As 4

𝜏𝑎𝑙𝑙 > , So the design is safe.

4.12 Design of front axle

Figure 4.15 front axle

Since the axle is supported and attached on the wheels by pin, bolt or another means so, it is
considered as a simply supported beam (A beam supported or resting freely on the supports at its
both ends). The materials selected for the axle have higher bending and shearing strength. Basically,
materials used for axle/shaft should have the following core properties:

62
  It should have high strength: therefore to with stand forces applied on it.
 It should have good machinability: for the easy of manufacturing.
 Good heat treatment properties: This provides the shaft with good surface
properties that can resist failures due to fatigue, wear and creep.
 It should have good wear resistance properties especially when there is a necessity to
use the axle with journal bearings and similar parts.
We have selected a steel (annealed) having AISI number 1020 with σt = 394.7Mpa and σy =
294.8Mpa, L =715mm, F.s = 2.5
The total weight applied on the axle is load of the mower and the force exerted by the user. The
support forces of the wheel are, R1 and R2; there fore

As the force is applied to the midpoint, the maximum bending moment is given by;
∑Fx =0 R1+R2 = 422N

But from symmetry R1 and R2 are equal.

Therefore, 2R1= 422N, R1= R2= 211 N
FL 422∗715
And, Mmax =
4
= 4
= 75432.5Nmm (the maximum moment is at the middle of the axle)
Considering the deflection or bending:
σy 294.8
σb =
S .F
=
2.5
= 117.9Mpa
(σb ) This is the allowable bending stress;
3
Mmax πd
σb= where, z=
Z 32
Then, for circular cross section we have,
(73850)(32)
117.9Mpa =
πd 3
63
d = 18mm, say 20mm
Considering shear stress:
The shear stress is applied at the wheel positions and it is due to the shear force of 211N.
Fs
𝜏=
As
Where, Fs - shear force applied As − Shear area
Fs
(211)(4)
τ = πd 2 = = 0.67Mpa
π 202
4
Therefore, the shear stress applied on the axle is less than the allowable stress. So, the above
diameter is safe.

4.13 Design of wheel bracket

Figure 4.16 wheel bracket

Material selection
Stainless steel
Uns no.-530300 AISI No.-303
Tensile strength-585Mpa
Yield strength-240Mpa
load 206 N
𝜎𝑐, 𝑚𝑎𝑥 =
c ross sectional are a
= 0.4∗0.22 m
=2340.9N/ M 2
240𝑀𝑝𝑎 > 0.002𝑀𝑝 , the design safe

4.14 Front Wheel Design

When the problem of grass trampling was identified and the new design was implemented, thin
front wheels were used to reduce the grass trampling effect and provide stability. The front wheel
64
brackets can also be adjusted to change the height of the bed knife, thus changing the height of the
grass that has been cut. This allows the operator to have full control over the outcome of using this
reel type lawn mower. The front wheel design can be seen in Figure 4.14:

Figure 4.16 Front wheel

Welding is extensively used in the fabrication of seed dispersing machine with the following
advantages:
 Welded structures are usually lighter than other joining such as riveted structures.
 Welded joints provide maximum efficiency which is not possible by other cases
 Alteration and additions can be easily made in existing structure
 Has greeter strength, often welded joints has the strength of the parent material.
 Provides very rigid joint
 No difficulty of joining complicated parts
 The process takes less time
But there are disadvantages like:
 Distortion due to uneven heating and cooling during fabrication
 Require high skill and supervision
 Failure due to crack development
 Inspection is more difficult
Therefore, lap joint or fillet joint and butt joint are selected to join the parts of the machine. Lap or
fillet joint is done by over lapping the plates and welding the edges of the plates. The cross section
of the fillet is approximately triangular. And butt joint is obtained by placing the plates edge to
edge.

65
4.16 Equipment and Component Guards

Figure 4.17 Safety guard

As with every power tool it is important to ensure the safety of the operator. This manual push reel
type lawn mower is equipped with a reel guard, belt guard, and equipment guard.

The reel guard is to protect the operator from projectiles that could be ejected from the reel as it is
spinning. The chain guard will prevent objects from being pulled into it as it is spinning at a very
high rate.

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1