Design 20

International Journal of Engineering Research and General ScienceVolume 2, Issue 5, August – September 2014
ISSN 2091-2730
Design, fabrication and Performance Evaluation of Polisher Machine of Mini

Dal Mill
Sagar H. Bagade1, Prof. S. R. Ikhar2, Dr. A. V. Vanalkar 3
1
P.G. Student, Department of Mechanical Engg, KDK College of Engineering, Nagpur, R.T.M. Nagpur University, Maharashtra,
[email protected] Tel.:- +919673702322
2
Asst. Professor, Department of Mechanical Engg KDK College of Engg. Nagpur, RTM Nagpur University, Maharashtra, India.
[email protected]
3
Professor, Department of Mechanical Engg KDK College of Engg. Nagpur, RTM Nagpur University, Maharashtra, India.
[email protected]
Abstract— This paper describes the detail information of design procedure of polisher machine. Pictorial views of fabricated
machine is given. The processed dal sample is tested for reflectivity. Schematic of test apparatus is given. Apparatus consist of LDR ,
which detects incoming light in the form of resistance. Three Dal samples are tested. Surface of Polished Dal samples found more
reflective than unpolished Dal sample.
Keywords— design, polishing, pigeonpea, mini dal mill, fabrication, experimentation, test setup.
1.0 INTRODUCTION
The cotyledon of dry seeds excluding seed coat is called dal. In India and many Asian countries, Pigeonpea is mainly consumed as
dhal acceptable appearance, texture, palatability, digestibility, and overall nutritional quality. The polishing is one of the important
value addition steps in Dal processing. The polishing is done to improve the appearance of the Dal, which helps in fetching premium
price to the processor. Whole pulses such as pea, black gram, green gram, and splits(dal) are polished for value adding. Some
consumers prefer unpolished dal, whereas others need dal with attractive colour( polished dal). Accordingly, dal is polished in
different ways such as nylon polish, oil-water polish, colour polish and so on. Polishing is a process of removal of outer layer from a
surface. The cylindrical roller mounted with hard rubber, leather or emery cone polisher and roller mounted with brushes are used for
the purpose. The powder particles are removed by rubbing action. Speed and sizes of these types of polisher are similar to those of the
cylindrical dehusking roller. Another type of machinery provided for this purpose is a set of screw conveyors arranged in battery for
repeated rubbings. The flights and shaft are covered with nylon rope or velvet cloth. The speed of each screw conveyor varies. The
repeated rubbing adds to the luster of the dal, which makes it more attractive. These polishers are commonly known as nylon polisher
or velet polisher, depending on material used and are available in a set of 2, 3, 4 or 5 screw conveyors. The splitting and polishing is
done to increase the shelf life of pigeon pea. The Dal mills are used for splitting of pulse into two cotyledons followed by polishing.
Seed treatment to reduce storage losses is becoming increasingly important.
2.0 DESIGN OF POLISHER MACHINE

This chapter gives the design calculation of major components of the machine, e.g. design calculation of shaft, belt and pulley drive.
2.1 DESIGN CONSIDERATION
Objective is to clean the surface of dal i.e. polish dal grains.
The value of force required to break dal grain is called as bio yield force. The machine is designed considering the bio-yield force of
dal grains. From literature it is found that this force is different for length, breadth and thickness. Among three minimum is at length
i.e. 81.06N.
F = 78.74 N
This much force is imparted on grains against the lower half inner periphery.
Hence,
1hp motor is selected.
2.2 Drive selection
Motor speed, N1 = 1440 rpm
Velocity, Vr = 8
Hence V-belt drive is selected for power transmission.
2.3 Design of V-belt drive
D1 = 58.8mm
Hence,1440 / 180 = D2 / 58.
136
www.ijergs.org
ISSN 2091-2730
D2 = 406mm
Checking,
Vp = π D1 N1 / 60
= 3.83 m/sec
The peripheral velocity(Vp) for de-hulling i.e. splitting is recommended 10 m/s.
1] Power per belt = (Fw – Fc )x (eμ/sin(α/2) – 1)x Vp = 2.378 kW
eμ/sin(α/2)
2] Number of belts , N = Pd / power peer belt = 0.345, N = 1
3] Length of belt , L = π/2(D2+D1) + 2C+ (D2 – D1 )2 / 4C = 1988 mm
Standard length of belt selected ,L = 77 inch
2.4 Design of bigger pulley
1) Width of pulley w = (n-1) e + 2f
For section-A, W = (n-1) e + 2 f = 21mm
2) Pitch diameter ,Dp
For v-groove details , α = 38 degree, Recommended Dp = 200mm
3) Type of construction
According to diameter of pulley , D2 = 406mm
Arm construction type selected
No. Of arms = 1,No. Of sets = 1
4) Rim thickness
T = 0.375 √D + 3 = 11mm
2.5 DESIGN OF MAIN SHAFT
1) DESIGN TORQUE
Td= 60xPxKl/(2xπxN )------ [Kl=1.75 for electrical motor and line shaft]
Td= 69.259 N-m
2) Forces on belt drive
Td = (T1 – T2)D2/2
(T1-T2) = 341.177 N-m -------------------------------(1)
T1/T2 = eμ
Where ,Coefficient of friction, μ= 0.3
Angle of lap on smaller pulley, = 2.364
T1/T2 = e0.3x 2.364
T1 = 2.032 T2--------------------------------(2)
From equation (1) and (2)
2.032 T2 – T2 = 341.177
T1 = 671.77 N , T2 = 330.6 N
2.6 FORCE CALCULATION ON MAIN SHAFT
Fig 2.1 Vertical shear force diagram

Weight of pulley , Wpa = 5.5kg = 54N
Weight of main shaft with rotor , Wsh = 15kg = 147.15N
At static equilibrium, Σ F = 0
Rvb + Rvd = 1203.62-----------------------------(1)
Taking moment at point B,
Hence, ΣMb = 0
Rvd = 144.1N
Substituting above value in equation (1)
137
www.ijergs.org
ISSN 2091-2730
Hence , Rvb = 1.59N
Fig 2.2 vertical bending moment

Ma = 0, Mb = - 160.58 N-m , Mc = -159.45 N-m, Md = 0
Selecting maximum moment on shaft
M = 160.58N-m
Selecting shaft material SAE 1030
Syt = 296Mpa, Syt = 296/2 = 148 Mpa, Tmax=0.3 x Syt = 44.4 Mpa
Sut = 527Mpa, Sut = 527/2 = 263.5Mpa, Tmax= 0.18 xSut = 47.43Mpa
Selecting Tmax = 44.4Mpa
For rotating shaft Selecting gradually applied load , Kb = 1.5, Kt =1
For diameter of shaft
Tmax = 16 x 10 x 3√(Kbx M)2 + (Ktx Td)2
πx Dsh3
Hence, Dsh = 30.63mm
Selecting standard diameter of shaft , Dsh =32mm
Hub diameter, Dh = 1.5 Dsh + 25 = 73mm
Hub length , Lh = 1.5 xDsh = 42mm
3.0 Fabrication
3.1 Mechanical Components
1) Roller with shaft 2) Upper Half Casing With Hopper
Fig.no 3.1Top View of Roller with Pulley Fig.no.3.2 Upper Half Casing With Hopper
3) Lower Half Casing With Frame 4) Polisher Machine
138
www.ijergs.org
ISSN 2091-2730
Fig.no.3.3 Lower Half with Velvet Bed Fig.no.3.4 Assembled Machine
4.0 EXPERIMENTATION
4.1 MATERIALS AND METHODS
Two samples are selected for testing. The first sample selected for testing is output product of a mini dal mill. This sample is dehusked
and split tur dal. It contains split unhusked grains, split husked grains, broken grains husk and dust. It is processed through oil mixing,
sun drying and dehusking.
Fig. Prepared Dal Samples

4.2 TESTING
4.2.1 TEST APPARATUS
Photo-conductive cell with a potentiometer is used to compare the shine of surface. Reflections of light from a surface of grains is
measured indirectly.
Fig.no.4.1 schematic of test apparatus Fig. no.4.2Test Apparatus

Principle of Working:
‗When light strikes semi-conductor material, there is decrease in cell resistance‘.
4.2.3TESTING RESULT
Three samples are tested for light reflectivity.10 tests are done on each sample and mean values are tabulated.
Results of testing are tabulated as below:
Sr. Dal Sample LDR 1 LDR 2
139
www.ijergs.org
ISSN 2091-2730
no. (KΩ) mean value (KΩ) mean value

1 Unpolished 0.2 0.92
2 Oil polished 0.12 0.74
3 Polished without oil 0.12 0.6
Table.no.4.3 Dal Sample Testing
1
0.8
0.6
0.4 LDR 1
0.2
0 LDR 2
UNPOLISHED OIL POLISHED POLISHED

WITHOUT OIL
Fig .4.4 Dal sample vs LDR readings
Decrease in resistance indicates increase in intensity of light striking LDR (LIGHT DEPENDENT RESISTOR i.e. Photo-Conductive
cell). Above table clearly indicates that grains samples of Tur Dal processed through Polisher Machine have better shine.
5.0 CONCLUSION
Decrease in resistance indicates increase in intensity of light striking LDR (LIGHT DEPENDENT RESISTOR i.e. Photo-
Conductive cell). Above table clearly indicates that grains samples of Tur Dal processed through Polisher Machine have better
shine. From above study, results shown that there is improvement in the textur of Tur dal.
REFERENCES:
[1] Mutalubi Aremu Akintunde ,‖Development of a Rice Polishing Machine ― , AU J.T. 11(2): 105-112 (Oct. 2007)
[2] Gbabo Agidi, Liberty J.T., Eyumah A.G., ―Design, Construction and Performance Evaluation of aCombined Coffee Dehulling and
Polishing Machine‖, International Journal of Emerging Technology and Advanced Engineering, Volume 3, Issue 11, November 2013
[3] Oduma O., Femi1 P.O. and Igboke M.E, ―assessment of mechanical properties of pigeon pea (cajanus cajan (l)millsp) under
compressive loading‖ , International Journal of Agricultural Science and Bioresource Engineering Research Vol. 2(2), pp. 35-46,
October, 2013
[4] Shirmohammadi Maryam, Yarlagadda P. K.D.V., Gudimetla P., Kosse V., ―Mechanical Behaviours of Pumpkin Peel under
Compression Test‖, Advanced Materials Research, 337(2011), pp. 3-9
[5] N. V. Shende,‖Technology adoption and their impact on formers : A Case study of PKV Mini Dal Mill in Vidarbha Region―Asian
Resonance , VOL.-II, ISSUE-IV, OCTOBER-2013
[6] Singh Faujdar andDiwakar B.,‖ Nutritive Value and Uses ofPigeonpea and Groundnut‖ ICRISAT, 1993
[7] Mangaraj S, Kapoor T,‖ Development and Evaluation of a Pulse Polisher‖, Agricultural EngineeringTodayYear : 2007, Volume :
31
[8] Mangaraj S. and SinghK. P.,‖ Milling Study of Multiple Pulses Using CIAE Dhal Mill for Optimal Responses―,J Food Process
Technol, Volume 2 • Issue 21 0.4172/2157-7110.1000110
[9] Kurien P. P., ―Advances in Milling Technology of Pigeonpea‖, Proceedings of the InternationalWor k shop onPigeonpeas, Volume
1, 15-19 December 1980
[10] Nwosu J. N, Ojukwu M, Ogueke C. C, Ahaotu I, and Owuamanam C. I., ―The Antinutritional Properties and Ease of Dehulling
140
www.ijergs.org
ISSN 2091-2730
on theProximate Compositionof Pigeon pea (Cajanuscajan) as Affected by Malting‖, International Journal of Life Sciences Vol.2.
No.2. 2013. Pp. 60-67
[11] Opoku A., Tabil1 L., Sundaram J., Crerar W.J. and Park S.J.,‖Conditioning and Dehulling of Pigeon Peas and Mung
Beans‖,CSAE/SCGR 2003, Paper No. 03-347
[12] Ghadge P N , Shewalkar S V, Wankhede D B,‖ Effect of processing methods on qualities of instant whole legume: Pigeon
pea(CajanuscajanL.)‖, Agricultural Engineering,International: the CIGR Ejournal. Manuscript FP 08 004. Vol. X. May, 2008.
[13] Shiwalkar B.D.,‘‘Design data for machine elements‘‘, 2010 Denett& Company.
[14] Rattan S.S, ‘‘Theory of machine‘‘, edition 2012, S.Chand Publication.
[15] Bhandari V.B., ‗‘Design of machine elements‘‘.3rd edition,2010 the Tata McGraw Hill Education Private Limited.
[16] Chakraverty A., MujumdarA.S, Ramaswamy H.S.,‖Handbook of Post-harvest Technology‖,2013 Marcel Dekker Inc.
[17] Kumar D.S. ,‖Mechanical Measurement‖, 5th edition,2013, Metropolitan Book Co. Pvt.Ltd
141
www.ijergs.org

Design 20

Uploaded by

Copyright:

Available Formats

Design 20

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Design 20

Uploaded by

Copyright:

Available Formats

International Journal of Engineering Research and General ScienceVolume 2, Issue 5, August – September 2014

Design, fabrication and Performance Evaluation of Polisher Machine of Mini

2.0 DESIGN OF POLISHER MACHINE

Fig 2.1 Vertical shear force diagram

Hence , Rvb = 1.59N

Fig 2.2 vertical bending moment

3) Lower Half Casing With Frame 4) Polisher Machine

Fig.no.3.3 Lower Half with Velvet Bed Fig.no.3.4 Assembled Machine

Fig. Prepared Dal Samples

Fig.no.4.1 schematic of test apparatus Fig. no.4.2Test Apparatus

no. (KΩ) mean value (KΩ) mean value

UNPOLISHED OIL POLISHED POLISHED

Fig .4.4 Dal sample vs LDR readings

[14] Rattan S.S, ‘‘Theory of machine‘‘, edition 2012, S.Chand Publication.

You might also like