Dry Coffee Processing Machine

DESIGN OF DRY COFFEE PROCESSING MACHINE 2015
ACKNOWLEDGMENT
We would like to express our deepest gratitude to, Lech Wubshet ,Lech Wossenu Ali ,Gebre
Mekial to give essential information about geometrical analysis of coffee and power
requirement of coffee hulled.
Next, we really like to appreciate the continuous support of our advisor Lech. Yalew D.
and all Mechanical staff members and our classmates for their comment on our progress.
Finally we thank our God for his endless love and support.
BY:
BESUFEKAD ESTIFANOS,HABTAMU G/ MARIAM,HUSSEN ALI AND WUDEST

FESHA
ITR/0228/03, IRT/480/03 ,ITR/535/03 ,ITR/986/03 RESPECTIVELY.
BSC MECHANICAL ENGINEERING
KOMBOLCHA INSTITUTE OF TECHNOLOGY, 2015 E.C
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ABSTRACT
Coffee is an important export commodity for Ethiopia contributing 41% of the country’s
total foreign exchange earnings (IMF, 2006) and about 10% of the gross domestic product.
But there is still a problem in the way coffee is processed which could lead to low quality
coffee 4 . Most farmers in Ethiopia process coffee cherries with a wet processing method
traditionally by hand equipments. And some small scale industries process dry coffees with
dry coffee processing machineries imported from abroad and some manufactured locally.
Comparing the two methods it is found that the dry method is simpler and needs smaller
area. Since most of coffee processing machine is comes from foreign countries as well as local
countries there is no processed quality coffee because those machines are not well processed
due to the huller and the blade of machines but, these problem can be solved by our design
machine. Because our design is to improve quality coffee can be easily processed by changing
of the blade and the huller of the machine by groove and hole of the perforated cylinder and
drum respectively.
The general objective of the project is to provide an effective of dry coffee processing
mechanism, which includes every machine component needed to produce a quality coffee.
And the specific objective of the project is to design the two basic components of the dry
coffee processing machine, the perforated cylinder and the threshing drum.
The design consist all the assumption and calculation used to determine the dimensions of
each machine parts including the assembly drawing model.
In this project, a new modified design of threshing drum is introduced which is simpler and
easy to manufacture. We also recommend other interested students and designers improve it
further and manufacture all the other components.
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TABLE OF CONTENT
Table of Contents page

ACKNOWLEDGMENT ............................................................................................................. i
ABSTRACT ............................................................................................................................... ii
LIST OF FIGURE ............................................................................................................................... vi
LIST OF TABLE ............................................................................................................................... viii
CHAPTER ONE ......................................................................................................................... 1
1. INTRODUCTION ..........................................................................................................................1
1.1 Problem Statement ........................................................................................................................2
1.2 Objective Of The Project ..................................................................................................... 2
1.2.1 General Objective ...................................................................................................................2
1.2.2 Specific Objective ....................................................................................................................2
1.3.1 Benefiters of Dry Coffee Huller Machine ...................................................................................3
1.4 Scope of The Project ....................................................................................................................3
1.5 Methodology.................................................................................................................................3
CHAPTER TWO ........................................................................................................................ 4
2. LITERATURE REVIEW .........................................................................................................................4
2.1 General description of coffee plan .................................................................................................4
2.1.1 Types of Coffee Bean Plants .......................................................................................................4
2.1.2 The Kona .....................................................................................................................................4
2.1.3 The Arabica .................................................................................................................................4
2.1.4 The Robusta ................................................................................................................................5
2.2 Traditional Coffee Huller Machine.................................................................................................6
2.3 Development of Plantation Machinery .........................................................................................6
2.4 Spectrum Coffee Huller ..................................................................................................................9
2.5 Cross Beat Coffee Huller .............................................................................................................10
2.6 Coffee Huller ................................................................................................................................10
2.7 Neelgiri Coffee Huller ..................................................................................................................11
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CHAPTER THREE .................................................................................................................. 12
3. Design Analysis of Dry coffee Processing Machine ......................................................................12
3.1 General Considerations in Machine Design ................................................................................12
3.2 Dimensions of coffee bean ................................................................................................. 13
3.3 Design of hopper..........................................................................................................................14
3.4 Geometrical analysis of drum .......................................................................................................15
3.5 Geometrical analysis of Perforated cylinder .............................................................................17
3.6 The shearing force of coffee .........................................................................................................18
3.7 power determination to the coffee ................................................................................................19
3.8 Design of belt and pulley .............................................................................................................20
3.9 Design Of Pulley..........................................................................................................................21
3.9.1 Design OF Pulley ON Shaft...................................................................................................21
3.9.2 Design of Pulley on Motor Shaft ...........................................................................................22
3.10 Design Of Key ...........................................................................................................................23
3.11 Design of the shaft ....................................................................................................................25
3.12 DESIGN OF V- BELT ..............................................................................................................29
3.13 Electrical Motor selection ..........................................................................................................31
3.14 Bearing selection .......................................................................................................................32
3.15 Sieve .........................................................................................................................................33
3.15.1 Design of sieve shaft ................................................................................................................35
3.15.2 Design of helical spring ...........................................................................................................37
3.15.3 Cam Design ............................................................................................................................39
3.15.4 Welding process.................................................................................................................41
3.16 Selection Of Fan .......................................................................................................................44
3.17 Frame .........................................................................................................................................45
3.18 Design Of Column .....................................................................................................................45
3.19 Design of beam .........................................................................................................................46
3.19.1 Checking Deflection On The Beam ......................................................................................47
3.20 Bolt and Nut Selection .............................................................................................................48
3 .21. Manufacturing Process Of Each Material .................................................................................48
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3.21.1 Manufacturing processed of spring......................................................................................48
3.21.2 Manufacturing processes of shaft .......................................................................................49
3.21.3 Manufacturing processes of the hopper ...............................................................................49
3.21.4 Manufacture of key: ...........................................................................................................49
3.21.5 Manufacture of perforated cylinder ....................................................................................49
3.21.6 Manufacturing of pulley: .....................................................................................................49
3.21.7 Manufacturing of sieve frame ..............................................................................................49
3.21.8 Manufacture of frame .........................................................................................................49
3.21.9 Manufacture of ball bearing................................................................................................49
3.21.10 Manufacturing process of threshing drum .........................................................................50
3.22 Cost analysis of material .......................................................................................................50
3.23 Maintenance of dry coffee processing machine ........................................................................51
CHAPTER FOUR .................................................................................................................... 53
4. Conclusion ......................................................................................................................................53
4.1 Recommendation ..........................................................................................................................54
4.2 Reference ............................................................................................................................ 55
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LIST OF FIGURE PAGE
Fig 2. Coffee bean plant------------------------------------------------------------------------------4
Fig 2.1 This Old-Fashioned Hulling Machine Is Operated by Ox Power in Venezuela------6
Fig: 2.1 This Old-Fashioned Hulling Machine Is Operated by Ox Power in Venezuela------6
Fig 2.2 Walker's Original Disk Pulpier, 1860 much favored in Ceylon and India-----------8
Fig; 2.3 Hand-power double-disks pulpier-----------------------------------------------------------9
Fig 2.4 Group of English cylinder coffee-pulping machine--------------------------------------9
Fig 2. 5 Spectrum industries--------------------------------------------------------------------------10
Fig 2. 6 Marshall fowler------------------------------------------------------------------------------10
Fig 2.7 v-mac industries------------------------------------------------------------------------------11
Fig 2. 8 Neelgiri---------------------------------------------------------------------------------------11
Fig 3.measurment of coffee---------------------------------------------------------------------------13
Fig 3.1 dimensions of coffee -------------------------------------------------------------------------13
Fig 3.2 rotating cylinder with perforated----------------------------------------------------------14
Fig 3.3 hopper------------------------------------------------------------------------------------------15
Fig:3.4 Geometrical analaysis of hopper-----------------------------------------------------------15
Fig 3.5 Threshing drum -------------------------------------------------------------------------------16
Fig 3.6 perforated cylinder----------------------------------------------------------------------------17
Fig 3.7 cross section of coffee huller ----------------------------------------------------------------17
Fig.3.8 shear force analysis of perforated cylinder-------------------------------------------------18
Fig,3.9 force acting on the perforated cylinder-----------------------------------------------------18
Fig 3.10 pulley diamention---------------------------------------------------------------------------21
Fig :3.11 dimension of pulley on motor--------------------------------------------------------------22
Fig:3.12 belt --------------------------------------------------------------------------------------------23
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Fig:3.13 dimension of shaft-------------------------------------------------------------------------26
Fig:3.14 forces applied on shaft A and B-----------------------------------------------------------26
Figure: 3.15 Bending moment diagram------------------------------------------------------------28
Fig:3.16 belt dimenstion------------------------------------------------------------------------------30
Fig:3.17 forces applied on sieve-----------------------------------------------------------------------34
Fig:3.18 bending moment diagram-------------------------------------------------------------------36
Fig. 3.19 helical spring---------------------------------------------------------------------------------37
Fig .3.20. cam and follower-----------------------------------------------------------------------------40
Fig :3.21 Dimension of cam----------------------------------------------------------------------------41
Fig:3.22 welding.----------------------------------------------------------------------------------------42
Fig:3.23 beam--------------------------------------------------------------------------------------------46
Fig:3.24 bending moment diagram-------------------------------------------------------------------47
Fig:3.25 diagram of deflection-------------------------------------------------------------------------47
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LIST OF TABLE PAGE
Table 3: dimensions of coffee cherry-----------------------------------------------------------------14
Tabel 3.1 Recomended table of pulleys of dimenstion----------------------------------------------22
Table3.2.proportin of standard parallel tapered key-------------------------------------------------24
Table:3.3 Recommended value for ultimate tensile strength and yield strength---------------25
Table:3.4 Recommended value for Km and kt ------------------------------------------------------28

Table 3.5 Material and belt density-------------------------------------------------------------------29
Table3.6 Recommended power range-----------------------------------------------------------------31

Table 3.7 Recommended table of helical spring----------------------------------------------------38
Table :3.8 symbol of welding--------------------------------------------------------------------------42
Table : 3.9 Recommended table of fan---------------------------------------------------------------45
Table: 3.10 formulas of second moment inertia----------------------------------------------------48

Table 3.11 dimension of bolt and nut,----------------------------------------------------------------48
Table: 3.12 cost analysis of material-------------------------------------------------------------------50
Table:3.13 Maintenance Schedule-------------------------------------------------------------------51
Table: 3.12 check list of material----------------------------------------------------------------------51
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CHAPTER ONE
1. INTRODUCTION
Coffee is one of the high value cash crops grown in Ethiopia with potential high quality for
domestic as well as international niche market. Among the various cash commercialization,
coffee is emerging as a likely agro-enterprise with great potential to provide farm employment
and income generation opportunities in the midil Ethiopia.
Coffee is cultivated in Ethiopia with no use of synthetic fertilizers and pesticides. This crop
has an important occupation in the rural economics with massive participation of marginal,
poor and down trodden class of rural communities, and has contributed for the soil
conservation, bio-diversity maintenance and watershed balance in the mid-hills of Ethiopia.
Coffee farming in Ethiopia is proven as promising due to the availability of soil with good
structure (physical and chemical) and appropriate microclimate in the mid hills. In Ethiopia,
dry processing was predominantly practiced in the past time.
The major problem currently facing Ethiopia coffee production is the great variation in the
quality of dried coffee beans. The problem comes from the fact that the coffee beans are
collected from the many small scale farmers and, in the absence of quality standards for
coffee, this has led to variation in quality.
Quality is defined as product performance that results in customer satisfaction and freedom
from deficiencies, in short fitness for use. Coffee is a complex product with attributes (flavor,
acidity, body, and aroma) that emerge from a combination of these characteristics displaying a
rich variability of that cannot be totally disintegrated . These natural variations of coffee that
complexly produce the final quality relate to different coffee varieties, soil altitude and rainfall
conditions and cultivation and processing methods used by producers in different producing
regions.
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1.1 Problem Statement
As we all know coffee is the backbone of our countries’ economy. But still there is a problem
on the way the coffee is processed apart from the traditional one. Among the methods of
processing, dry processing is the most common and effective way for our country. In Ethiopia
there are industries which process coffee using machineries imported from foreign countries
and some small scale processing industries use locally manufactured dry Coffee processing
machines. The problem lies on the effectiveness of the machineries. Some components of the
machines are still imported from abroad like the Blade of the Huller because it is very difficult
to manufacture it locally, by considering the dimension of the dry cherry and also the quality
of the finished product is not good. Because there is no enough grading mechanism as a result
of this, we solve the above problem by designing the huller and the grading mechanism.
1.2 Objective Of The Project

1.2.1 General Objective
The major objective of the project is to design the mechanism of a dry
Coffee processing machine.
1.2.2 Specific Objective

 The project specifically focuses on the design of the two major components of the dry
coffee processing machine, the perforated cylinder and thrusting drum .
 Provide new modified model of huller, with easy manufacturing process locally
available.
 The grading mechanism
 The design includes material selection, mechanism design, dimensional analysis,
determining power requirement, strength analysis, vibration analysis, and 3D model.
1. 3 Benefits Of Dry Coffee Huller Machine
Dry coffee processing machine is preferable than wet processing machine regarding to
our countries and also the type of coffee that growth in Ethiopia us we know our
country is 13 months of sun shine hence, there is no shortage of sun. by using dry
coffee processing machine we can get or achieve the following benefits. Concerning
the weather condition and farmers we can get the following benefits. these are
 Saving of water
 Minimization of production process
 Minimization of labour that can used for the production
 It can facilitate coffee supplying process for the customer
 Since the machine is simple and not complicated any one can operate
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1.3.1 Benefiters of Dry Coffee Huller Machine

 Farmer
 Domestic customer since us we know our people don't have enough
money to purchase the coffee that process by wet process because it
is costly
1.4 Scope of The Project

The scope of this project is to design the two main components of dry coffee processing
machine, the perforated cylinder and the threshing drum.
The design includes material selection, mechanism design, dimensional analysis, power
requirement, strength analysis, , component selection, and 3D model.
1.5 Methodology
Source
 Company observations
 Interview with key persons
 Internet
The above source helps us to identify the general working principle and mechanisms of dry
coffee processing machine.
Literature review: It is the methods of knowing information from recent to still to now.
Since It is used to help for our design by compare and contrast of literature review.
Geometric analysis: The method of knowing the overall dimensions of perforated cylinder
and threshing drum.
Design analysis: It is the third methods of methodology these can be used to design of each
part. It includes material selection and calculations of the part if necessary factor of safety it
must be calculate.
Manufacturing and cost analysis: These is the main parts of our deign to know how to
manufacture of parts and it indicates machinability of parts, after that to know the price(cost)
of each material.
Maintenance schedule: These are essential to our design because to know the major cause
and effect of falurity of each parts with its solution.
3D modeling: It is assembly parts of our machine
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CHAPTER TWO
2. LITERATURE REVIEW
2.1 General Description of Coffee Plan
2.1.1 Types of Coffee Bean Plants

For the record of information, there are more than six thousand variations of coffee beans
worldwide but only 25 of it are considered as the major types. And from these 25 major
types there are only three important and common types used by the consumers. Different
Species of the coffee bean plant includes. Coffee Arabica, Coffee Benghalensis, Coffee
canephora, Coffee congensis Coffee excelsa,Coffee gallienii, Coffee bonnieri, Coffee
mogeneti. Coffee liberica and Coffee stenophylla. The seeds or coffee beans of the different
plants produce coffee with slightly different characteristics.
Fig 2. Coffee bean plant 11
The three main types of coffee beans are Coffee Arabica, (simply referred to as Arabica), kona
and Coffee Canephora commonly referred to as Robusta. These two coffee beans (Arabica &
Robusta) types make up over 90% of coffee beans sold all over the world.
2.1.2 The Kona

Compared to Robusta and Arabica in the commercial world, Kona is much smaller yet very
expensive. This type of coffee bean normally grows in the country of Hawaii. Though Kona
is not being patronized as much by most common people in the market, it still has a very
high demand worldwide due to its powerful aroma. Having a very powerful aroma and
desirability, Kona is rarely blended with other kinds of drink flavorings.
2.1.3 The Arabica

Unlike Robusta, the Arabica type of coffee beans covers 60% of the coffee production in
the whole world because of the large bush that Arabica plants have. Also Arabica plants are
very vulnerable to pests, disease and frost. With this reason, the coffee beans of Arabica
plants are extremely expensive. Arabica coffee beans can be used on its wholesome form as
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well as it can be used as a base with Robusta for coffee blends. However, Arabica has a
very delicate flavor that can be used as add-ons on the flavorings of coffee blends.
But Arabica coffee beans still vary accordingly to the region where they are grown and
used. In South and Central America, the Arabica coffee beans have the moderate aroma and
body, which are used mostly for breakfast blends with American flavored coffees. Arabica
coffee beans produce a superior grade of coffee known as the gourmet coffee because it
contains half of the Robusta caffeine as well as more aromatic properties and desirable
flavorings. Being a worldwide coffee variation, Arabica coffee beans are able to meet a
fraction of the standard provide by the Specialty Coffee Association of America.
The Arabica type of coffee beans has the most flavored profiles while Robusta is grown
predominantly because of its ability and hardiness to thrive. Also Arabica has the various
distinct flavors and characteristics of coffee beans. Under the Arabica type of coffee beans
there are variations as well that are named after the region or country where they are found
predominantly or have originated. In some countries like Ethiopia, there are numerous
expensive variations of Arabica coffee beans growing in every regions of the whole country.
There are more variations of Arabica coffee beans found in country of Africa because the
country is the first one in the entire world that valued drinking coffee.
Three of the topmost variations of Arabica coffee are found in Africa as well namely the
Yirgacheffe, Sidamo and Harrar.
Kenya is also one of the countries where Arabica plants beans are cultured for coffee
drinking. It calls its Arabica coffee beans as Kenyan. Other countries where Arabica coffee
beans are produced include Uganda and Tanzania. Uganda also majorly produces Robusta
coffee beans. Few of the variations of Arabica coffee beans are to be found in Indonesia
and Java is the most popular variation in the country. Java variation adapted its name from
the region of Java in Indonesia. Throughout the time, it had become synonymous with the
word coffee itself. More variations of Arabica coffee beans are also found in Hawaii where
the popular variation was called the "Hawaiian Kona", which grows on the Mountain
Hualapai’s slopes.
2.1.4 The Robusta

Robusta coffee beans are favored more for their Robusta coffee blends. Robusta coffee is
Considered a lower grade of coffee, as it is usually grown at lower elevations. It has a more
astringent flavor and contains a higher amount of caffeine. Robusta trees are normally
easier to grow and simpler to maintain. They are also more resistant to disease and produce
a higher yield. The Robusta types of coffee beans are typically used to produce a lower
Priced coffee blend. The types of coffee beans and/or coffee blends are more usually
identified by geographic location rather than primary coffee bean type. These includes the
Tanzanian Peaberry, the Kona Pea berry and Kona Extra Fancy from Hawaii, the Organic
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Sumatra Reserve, the Madriz from Nicaragua Klatch, from the Yirgacheffe region of Ethiopia
and he Bourbon Santos from Brazil.
2.2 Traditional Coffee Huller Machine

LA ROQUE in his description of the ancient coffee culture, and the preparation methods as
followed in Yemen, says that the berries were permitted to dry on the trees. When the outer
covering began to shrivel, the trees were shaken, causing the fully matured fruits to drop upon
cloths spread to receive them. They were next exposed to the sun on drying-mats, after which
they were husked by means of wooden or stone rollers. The beans were given a further drying
in the sun, and then were submitted to a winnowing process, for which large fans were used.
Fig :2.1 This Old-Fashioned Hulling Machine Is Operated by Ox Power in Venezuela 3
2.3 Development of Plantation Machinery

For hulling dry cherry coffee there are several excellent makes of machines. In one style, the
hulling takes place between a rotating disk and the casing of the machine. In another, it takes
place between a rotary drum covered with a steel plate punched with vertical bulbs, and a
chilled iron hulling-plate with pyramidal teeth cast on the plate. Both are adjustable to
different varieties of coffee. In still another type of machine, the hulling takes place between
steel ribs on an internal cylinder, and an adjustable knife, or hulling blade, in front of the
machine.
At least two score of different makes of pulping machines are in use in the various coffee-
growing countries. Pullers are made in various sizes, from the small hand-operated machine to
the large type driven by power; and in two general styles cylinder, and disk.
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The cylinder pulpier, the latest style suggesting a huge nutmeg-grater consists of a rotary
cylinder surrounded with a copper or brass cover punched with bulbs. These bulbs differ in
shape according to the species, or variety, of coffee to be treated.
Arabica, liberica, robusta, canephora, or what not. The cylinder rotates against a breast with
pulping edges set at an angle. The pulping is effected by the rubbing action of the copper
cover against the edges, or ribs, of the breast. The cherries are subjected to a rubbing and
rolling motion, in the course of which the two parchment-covered beans contained in the
majority of the cherries become loosened. The pulp itself is carried by the cover and is
discharged through a pulp shoot, while the pulped coffee is delivered through holes on the
breast. Cylinder machines vary in capacity from 400 pounds (hand power) to 4,800 pounds
(motive power) per hour.
Some cylinder pullers are double, being equipped with rotary screens or oscillating sieves, that
segregate the imperfectly pulped cherries so that they may be put through again. Pulpers are
also equipped with attachments that automatically move the imperfectly pulped material over
into a repassing machine for another rubbing. Others have attachments partially to crush the
cherries before pulping.
The breasts in cylinder machines are usually made with removable steel ribs; but in Brazil,
Nicaragua, and other countries, where, owing to the short season and scarcity of labor, the
planters have to pick, simultaneously, green, ripe, and over-ripe (dry) cherries, rubber breasts
are used.
Many scientists are created coffee huller machines among them the following are listed below.
William Panter was granted the first English patent on a "mill for husking coffee." This was in
1775. James Henckel followed with an English patent, granted in 1806, on a coffee drier, "an
invention communicated to him by a certain foreigner." The first American to enter the lists
was Nathan Reed of Belfast, Me., who in 1822 was granted a United States patent on a coffee
huller. Roswell Abbey obtained a United States patent on a huller in 1825; and Zenos
Bronson, of Jasper County, Ga., obtained one on another huller in 1829.
John Walker was granted (1860) an English patent on a disk pulper in which the copper
pulping surface was punched, or knobbed, by a blind punch that raised rows of oval knobs but
did not pierce the sheet, and so left no sharp edges. During Ceylon's fifty years of coffee
production, the Walker machines played an important part in the industry. They are still
manufactured by Walker, Sons & Co., Ltd., of Colombo, and are sold to other producing
countries.
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Fig 2.2 Walker's Original Disk Pulpier, 1860

much favored in Ceylon and India 4
George L. Squire began the manufacture of plantation machinery in Buffalo, N.Y., in 1857.
He was active in the business until 1893, and died in 1910. The Geo. L. Squier Manufacturing
Co. still continues as one of the leading American manufacturers of coffee-plantation
machinery.
Marcus Mason, an American mechanical engineer in San José, Costa Rica, invented (1860) a
coffee pulper and cleaner which became the foundation stone of the extensive plantation-
machinery business of Marcus Mason & Co., established in 1873 at Worcester, Mass
Fig ;2.3 Hand-power double-disk pulpier 4
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William Van Vleek Lidgerwood, American chargé d'affaires at Rio de Janeiro, was granted an
English patent on a coffee hulling and cleaning machine in 1866. The name Lidgerwood has
long been familiar to coffee planters. The Lidgerwood Manufacturing Co., Ltd. has its
headquarters in London, with factory in Glasgow. Branch offices are maintained at Rio de
Janeiro, Campinas, and in other cities in coffee-growing countries.
Probably the name most familiar to coffee men in connection with plantation methods is
Guardiola. It first appears in the chronological record in 1872, when J. Guardiola, of Chocola,
Guatemala, was granted several United States patents on machines for pulping and drying
coffee. Since then, "Guardiola" has come to mean a definite type of rotary drying machine
that—after the original patent expired—was manufactured by practically all the leading
makers of plantation machinery. José Guardiola obtained additional United States patents on
coffee hullers in 1886.
Fig 2.4 Group of English cylinder coffee-pulping machines 4
William Van Vleek Lidgerwood, Morristown, N.J., was granted an English patent on an
improved coffee pulper in 1875.
The above machines are used or functional in previous now a days the coffee industry uses so
many machines among these the following are listed below
2.4 Spectrum Coffee Huller

This high efficiency "Spectrum Coffee Huller" can be used for hulling both parchment and dry
cherry coffee.
This hulling method is extremely efficient resulting in higher outputs with lower power
consumption. The friction between the coffee beans is minimum and therefore there is no loss
due to the generation.
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Fig 2. 5 Spectrum industries 3
2.5 Cross Beat Coffee Huller

Salient Features:
* Finest hulling results even with high percentage of small cherries.
* Easy to adjust, quadruple use by inversion of two-piece hulling drum, mistake-proof fitting,
made of low-abrasion sheet steel with special perforations and indentations and individual
drive for each component .
Fig 2. 6 Marshall fowler 3
2.6 Coffee Huller

V-MAC Cross Beater type Coffee Hullers is extremely efficient in hulling dry cherry coffee.
The friction between the coffee beans is minimum therefore there is no loss due to the
generation of coffee dust or breakage of beans.
Fig 2.7 v-mac industries 3

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2.7 Neelgiri Coffee Huller
improved type heavy duty fitted with self aligning ball bearing, blower type with steel barrel
suitable to both Arabica and Robusta Cherry and Parchment Coffee.
Fig 2. 8 Neelgiri 3
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CHAPTER THREE
3. Design Analysis of Dry coffee Processing Machine
3.1 General Considerations in Machine Design
Following are the general considerations in designing a machine component :
1. Type of load and stresses caused by the load. The load, on a machine component, may act
in several ways due to which the internal stresses are set up. .
2. Motion of the parts or kinematics of the machine. The successful operation of any machine
depends largely upon the simplest arrangement of the parts which will give the motion
required.
The motion of the parts may be :
(a) Rectilinear motion which includes unidirectional and reciprocating motions.
(b) Curvilinear motion which includes rotary, oscillatory and simple harmonic.
(c) Constant velocity.
(d) Constant or variable acceleration.
3. Selection of materials. It is essential that a designer should have a thorough knowledge of
the properties of the materials and their behavior under working conditions. Some of the
important characteristics of materials are : strength, durability, flexibility, weight, resistance to
heat and corrosion, ability to cast, welded or hardened, mach inability, electrical conductivity.
4 . Form and size of the parts. The form and size are based on judgment. The smallest
practicable cross-section may be used, but it may be checked that the stresses induced in the
designed cross-section are reasonably safe. In order to design any machine part for form and
size, it is necessary to know the forces which the part must sustain. It is also important to
anticipate any suddenly applied or impact load which may cause failure.
5. Frictional resistance and lubrication. There is always a loss of power due to frictional
resistance and it should be noted that the friction of starting is higher than that of running
friction.
It is, therefore, essential that a careful attention must be given to the matter of lubrication of
all surfaces which move in contact with others, whether in rotating, sliding, or rolling
bearings.
6. Convenient and economical features. In designing, the operating features of the machine
should be carefully studied. The starting, controlling and stopping levers should be located on
the basis of convenient handling. The adjustment for wear must be provided employing the
var+6ious take up devices and arranging them so that the alignment of parts is preserved. If
parts are to be changed for different products or replaced on account of wear or breakage, easy
access should be provided and the necessity of removing other parts to accomplish this should
be avoided if possible.
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The economical operation of a machine which is to be used for production, or for the
processing of material should be studied, in order to learn whether it has the maximum
capacity consistent with the production of good work.
3.2 Dimensions of coffee bean

The experimental data have been obtained for 20 different beans of the Robusta coffee were
produced in Brazil(B),Colombia(C),Cistercian(CR),Ethiopia(E)….etc the abbreviations in
square bracket indicate the coffee type. All analysis was performed for samples of 20 beans
randomly selected from each lot. Dimensions in the main axes (D1, D4, D7) correspond to w
(width), D (depth) and L (length) respectively.
Fig 3.measurement of coffee
Fig 3.1 dimensions of coffee
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Illustration of measuring sides for coffee beans

Table 3: dimensions of coffee cherry
Coffee brand Coffee No Mean w Mean Mean depth Mean length
(g) widthD1(mm) D4(mm) D7(mm)
B1 1 0.29±0.026 8.48±0.46 9.10±0.32 11.38±0.91
B2 2 0.280±0.023 8.36±0.54 8.9±0.26 10.85±0.99
C1 3 0.27±0.022 7.98±0.47 9.00±0.24 10.19±0.99
C2 4 0.302±0.023 8.43±0.47 9.2±0.52 11.43±2.24
C3 5 0.299±0.029 8.05±0.58 98.9±0.35 10.83±1.30
From the above listed information we select the Robusta coffee were produced in our country
because we design the huller machine by considering Robusta coffee that produced in
Ethiopia with the following dimensions.
By knowing the dimensions of coffee cherry by using caliper tool it can be determine the
width of coffee cherry, length of coffee and depth of coffee cherry from we take 5 coffee
cherry samples, so the result can be as follows in the table below.
 Mean weight of coffee cherry  0.3g

 Mean weight of coffee bean =0.28g
 Mean weight of coffee husk=0.02g
 Mean width D1 8.4mm
 Mean depthD4 9.2mm
 Mean length D7 11.3mm
Fig 3.2 rotating cylinder with perforated 3
3.3 Design of hopper

Hopper is one of the dry coffee processing machine that is used to carry coffee cherries. It is
located at the top of the dry coffee processing machine. The capacity ,angle of response
parchment coffee and space are important factors to be considered .assure frustum at the top
and bottom respectively, with each side inclined at 45° to the horizontal .the hopper was
made up of milled steel plate with trapeiozodal shape to serve as out let forth material.
Material selection of hopper: Due to carry high loads of coffee we select mild steel metal due
to strength. Our hopper contains 30kgof coffee cherry.
KIOT PAGE 14
Fig 3.3 hopper
From the above figer to determine geometrical analysis of hopper by using trapezoidal
systems it can be know the area and volume of hopper.
where 𝜃 = 45°
Fig:3.4 Geometrical analaysis of hopper
from Area relation we find that :sin45°=h/p
cos45°=180/p, p=180/cos45°=180/√2=106mm
sin 45°=h/106 , Hence,h=106×sin45=106√2=149mm

A 2
A2 : A12=1/2bh=1/2180*149=22350mm 22=100*149=14900mm
A3 = 60*100=6000mm2=0.06m2
A1=400*400=160000m2=0.016m2
the thiknes of the huper from the above figer is 3mm thick volume of huper
VA1=0.4×0.4×0.4=0.064m3
3.4 Geometrical analysis of drum

From the dimensions of coffee cherry we can determine the geometric analysis of threshing drum
because due to the effect of coffee on the drum it can be described easily.
 The length of drum L=300mm

 The diameter of the drum hole D=11.3mm
KIOT PAGE 15
 The depth of the hole(h)=3.1mm
 the width of the hole w=8.2mm
 the gap between one hole to the other hole are=5mm
 thickness of drum=10mm
 the diameter the drum d=200mm
t=10 mm
Fig 3.5 Threshing drum

 Material selection of threshing drum: Due to shearing force of coffee we select mild
steel metal due to strength.
 The drum hole for one raw contains 18 coffee cherry and one column contains12
coffee cherry ,then the drum hole contains (12*18=216 coffee cherry)
It can determinate coffee applied load on a drum
 applied load on the drum =m.a
pd=m*a however, in the form of acceleration we can use
gravity.(g=10m/s)
for one mass of coffee cherry we can get 0.3g hence, 216 coffee cherry has
(216*0.3g=0.064kg).Therefore pd=0.064kg*10m/s=0.64N
KIOT PAGE 16
3.5 Geometrical analysis of Perforated cylinder
Selections of Material: milled steel
Due to the occurrence of corrosion on this part , this material is essential for good corrosion
resistance .good wearing resistance, low maintenance and higher working harding rate.
Fig 3.6 perforated cylinder

 Height of groove on preforated cylinder =2.5 mm
 Length of groove on the preforated cylinder = 11.3 mm
 Depth of groove = 9.2 mm
Fig 3.7 cross section of coffee huller
A=effective arc length of the curved plate in which the hulling action takes place
B=the portion of whole coffee passing through the next step
length of the arc (A)=n*2πr/360°,therfore 50*113.75*2*π/360°=99.26mm and
area of arc(A)=1/2(θ-sin θ)*r2
1/2(50-sin50)*(113.75)2=2800mm2
KIOT PAGE 17
3.6 The shearing force of coffee
Fig.3.8 Shear force analysis of perforated cylinder
A.
B.
Fig,3.9 Force acting on the perforated cylinder
Strength of coffee cherry would be 0.314N/mm2,then the weight of coffee must be

(F=W=mg) therefore,
F=W=0.0003kg*10m/s2=0.003N ,
KIOT PAGE 18
The total mass of coffee cherry =216*0.003 Kg =0.0648 kg
F tot =0.0648× 10 𝑚/𝑠𝑒𝑐=0.648N =F load

F (for one coffee cherry )
τ= Where, τ - shear force of coffee applied on perforated cylinder
𝐴
A- contact area of coffee between perforated groove
a - length of groove ,
b - width of groove
0.003N
τ= π×5.6×4.6 mm 2 = 370.89𝑃𝑎
For the total shear stress on perforated cylinder is to multiply by one coffee cherry shear stress
so, for 1 coffee cherry = 370.89 Pa
216 coffee cherry =?
Total shear stress = 80.11 K pa ,So these shear stress is applied on the perforated cylinder due
to the shearing of coffee cherry.
3.7 power determination to the coffee

 To considers the following things
 Diameter of drum
 Speed of drum
 Impact force of coffee cherry
 Area of drum hole
The power required to hull the coffee is derived from the impact strength of the coffee, one
coffee cherry has 0.314N/mm2impact strength.
Fim
τ im= Where , A=area of drum hole
𝐴
Fim =impact force coffee cherry
τ im=impact shear force(impact strength of coffee cherry)
F im= 𝜏 im*A= 𝜏 im**π× 𝑎𝑏 = 0.314N/mm2× π ∗ 4.6 ∗ 5.6 = 25.39 N so,
For one coffee cherry impact force is 25.39N

π∗d∗N
V= Where, N-Speed of drum(rpm)
60
KIOT PAGE 19
d-diameter of drum(m)
V- velocity of drum(m/sec)
π∗0.2∗120
= =1.256 m/s
60
P =F× 𝑉 𝑤𝑕𝑒𝑟𝑒, 𝐹 − 𝑖𝑚𝑝𝑎𝑐𝑡 𝑓𝑜𝑟𝑐𝑒 𝑜𝑓 𝑜𝑛𝑒 𝑐𝑜𝑓𝑓𝑒𝑒 𝑐𝑕𝑒𝑟𝑟𝑦(𝑁)
V- Velocity of the drum(m/sec
P- power
= 25.39 N ∗ 1.256m/ sec = 31.9 watt so, for one coffee cherry to hulled, it needs 31.9
watt . for one revolution it contains 216 coffee cherry hence, to determine the total coffee
cherry power required to multiply for one coffee cherry power use.
1 coffee cherry = 31.9 watt
216 coffee cherry = x?

216 coffee cherry ×31.9 𝑤𝑎𝑡𝑡
so, x= = 6.88 𝐾𝑊
1 𝑐𝑜𝑓𝑓𝑒𝑒 𝑐𝑕𝑒𝑟𝑟𝑦
Therfore,the total coffee hulled by the drum with in 1rev required 6.88 Kw power.
We can determine the working time of our machine, the drum contains for one revolution
0.064Kg coffee cherry
For (1rev= 0.064Kg )coffee cherry and then for one second it takes two revolution of the
drum rotate so, for one minute (60sec) is 7.68Kg of coffee cherry are hulled.
3.8 Design of belt and pulley

The following important points should be noted before designing the belt and pulley.
The pulleys should not be too close together ,in order the arc of contact of the smaller
pulley may be as large as possible.
 Speed of the driving and driven shafts
 Power to be transmitted
 Center distance between the shafts
 Service conditions
KIOT PAGE 20
3.9 Design Of Pulley

Pulleys are used to transmit power from one shaft to another by means of flat belt-belt or
rope. Since the velocity ratio is the inverse ratio of the diameter of driving and driven
pulleys,therfore the pulley diameter should be carefully selected in order to have a desired
velocity ratio. The pulleys must be imperfect alignment in order to allow the belt to travel in
alien normal to the pulley forces.
The pulleys may be made of cast iron ,cast steel or pressed steel, wood and paper. the cast
material should have good friction wear characteristics .Hence, we select the material for
pulley cast iron ,it has low cost ,good casting characters tics ,high compressive strength, wear
resistance and excellent Machinability .the compressive strength of cast iron is much greater
than the tensile strength.
In order to calculate the speed ratio and the diameter we have to select the following data from
standared table
Dimeter (D) and setting the spped of the two pulleys are in the following way
3.9.1 Design OF Pulley ON Shaft
Fig 3.10 pulley diamention
Where, B = face widith
KIOT PAGE 21
Tabel 3.1 Recomended table of pulleys of dimenstion 1
Face width (B) = 2f+e, B= 35mm

d =15mm ,but pitch line is 375mm -15 mm= 360 mm so we select 8 mm thickness pulley
will be done.
3.9.2 Design of Pulley on Motor Shaft
Fig :3.11 dimension of pulley on motor
Pitch line diameter =140 mm
Face width =26 mm , radius of motor pulley = 150 mm
The speed ratio=d1N1=d2N2
But d1=150mm,N1=300Rpm,N2=120Rpm, d2=?
KIOT PAGE 22
Fig:3.12 belt
d1N 150∗300
d2= = = 375 𝑚𝑚
𝑁2 120
𝑁1 𝑑2 300 375
Speed ratio= 𝑁2 = 𝑑1 = 120 = 150 , 2.5 = 2.5
3.10 Design Of Key

key can be defined as machine element that is used to connect the transmission of shaft to
rotating machine element like pulley, gears ,sprockets or flywheel
 key is used to transmit the torque from the shaft to the hub of matting element
 to prevent relative rotational motion between the shaft and joined machine.
keys are made of plain carbon steel like 45c8 or 50c8 in order to with stand shear and
compressive stress resulting from transmission of torqe.there are so many types of key ,from
them we select rectangular sunk key .it is suitable for heavy duty application ,since there is no
possibility of the key to slip around the shaft . so it is appositive drive .crushing and shearing
of the key and the shaft are : σ c=70mpa and τ=42mpa
We select a shaft diameter 50 mm ,key width(w) and thickness(t) 12 mm and 8 mm
respectively.
In order to calculate key length first we consider the shear strength of the key.
T=L×W×τ×(d/2), where T-- torque
T=L*12×10-3×42×106*(50*10-3/2)=12600LNm ----------(1)
And torsion shearing strength (or torque transmitted) of the shaft,

𝜋
T= 16 × 𝜏 ∗ 𝑑3 = 1030.8 Nm -------------------------------------(2)
1030 .8 𝑁𝑚
by using equation1 and equation2 L= = ,L=40 mm
12600 𝑁𝑚
KIOT PAGE 23
Table3.2.proportin of standard parallel tapered key 1
KIOT PAGE 24
3.11 Design of the shaft
Selection of Materials; the best material is one, which serves the desired objective at the
minimum cost. The following factors are considered while selecting the material:
availability of the materials, suitability of the materials for the working conditions in
service, and the cost of the materials. The material used for the shaft is steel (40 C 8)
which have the following mechanical properties that is ultimate tensile (560 – 670) MPa
strength Yield strength 320 MPa because it have high strength, good mach inability, low
notch sensitivity factor, have good heat treatment properties and high wear resistant
properties. The shaft is used to attach the motor with the pulley pre cleaner.
Table:3.3 Recommended value for ultimate tensile strength and yield strength 6
Indian standard designation Ultimate tensile strength , Yield strength ,Mpa
M pa
40 C8 560- 670 320
45 C8 610 -700 350
50 C4 640 -760 370
50 C12 700 390
 It takes ultimate tensile strength ( 560-670) M pa

 yield strength 320 M pa
 A and D are the pulleys for the holler shaft
 B and C are bearing
 the shaft transmit 6.89 K w at120rpm
 the pulley weight WA=W g=49.9N
 for shaft material to use steel with permissible shear stress of 63Mpa
 mass of the shaft is negligible compared to the pulleys
 shock factor for bending
 shock factor for torsion
KIOT PAGE 25
Fig:3.13 dimension of shaft
We know that torque transmitted by the shaft

P∗60
T= , from the above by subsisting power and rpm
2𝜋𝑁
6.89×60
= =559 .29 Nm
2π∗120
T1 from the tight side=3035.6 N, T2 from the slack =718.9 N
Therefore ,Total vertical load acting on down ward on the shaft
T1 + T2 + WA
=718.9 N+3035.6 N+49.2N=3.79 K N
Fig:3.14 forces applied on shaft A and B

∑FY=0, RB+RC=RD +RA
RB +RC =7.59 KN-------------------------------(1)
∑MA =0, RB (0.075) +RC (0.35) =RD (0.45)--------------------(2)
By using Simmentals equation RC =3.79 KN
Then RB =7.59 KN-3.79 KN =3.79 KN
KIOT PAGE 26
To determine bending moment by using formulas by
section x-x
A.
but x=74.49=75mm, then
MX =X*3.79 KN
MX=0.075×3.79 KN =284.25 N.m
Section y-y
B.
∑MY =0, MY +RA× 𝑋 = 𝑅𝐵(𝑋 − 0.075) but,
3.79 KN*X=RB*X-0.075*3.79 KN
X=374.99mm=375mm hence, MY=(3.79 KN*0.075+0.075*3.79 KN - 0.375*3.79
KN )= -(852.75 Nm)
Where the (-ve) sign indicates the moment is down ward.
KIOT PAGE 27
Figure: 3.15 Bending moment diagram

Table:3.4 Recommended value for Km and kt 1
KIOT PAGE 28
From bending moment diagram we can see that the bending moment is maximum of the shaft
frame B to C maximum bending moment M=852 Nm
We know that the equivalent twisting moment
Te = 𝐾𝑚 ∗ 𝑀 2 + (𝐾𝑡 ∗ 𝑇)2
= 𝐾𝑚 ∗ 𝑀 2 + (𝐾𝑡 ∗ 𝑇)2 =
( 1.5 ∗ 852)2 + (1 ∗ 559)2 = 1165.2𝑁𝑚
We also know the equivalent twisting moment are
π∗τ∗d3
Te= therefore,
16
𝜋
1165.2 Nm = 16 *42× 106 ∗d3
1165.2∗16
d3 = 𝜋∗42×10 6
3
d= √14.12 × 10−5 = 52 𝑚𝑚 from standard it select 50 mm diameter of shaft.
3.12 DESIGN OF V- BELT

We select V- belt by application standard the angle of the groove on the pulley for V-belt is
34 from standard (32° to 38°).
The material used for the belt is rubber which cross section area is 608 mm2 and its density is
1140Kg/m3 ,the allowable tensile strength is 2 Mpa and coefficient of friction between the
pulley rim.
We select for our project v-belt for the following advantages-belts are very essential
compared to the other belt it have
 smooth starting and running
 silent operation
 long service life
 easy installation
 highly efficient
Table3.5 Material and belt density 6

Material of belt Mass density in kg/m3
Leather 1000
Canvass 1220
Rubber 1140
Balata 1110
Single woven belt 1170
Double woven belt 125
KIOT PAGE 29
Fig:3.16 belt dimenstion

𝜇 = 0.54 − 42.6/(152.6 + 𝑉) ,Where V: velocity of belt
𝜋∗𝑑1∗𝑁1 𝜋∗0.375∗300
V= = =2.8 m/s =3 m/sec
60 60
𝑑2−𝑑1 0.375−0.15
Hence for one belt sin𝛼 = =
2∗𝑥 2∗800
α = sin-1 (0.375-0.15)/2*8=5°
The angle of lap on the smaller pulley and the larger pulley
θ1 =180°-2 α * = 180° -2*5° =170°
θ2 =180° +2 α =180°+2*5° =190°
𝜋
On the form of rod θ1 =170°∗ 180 =3rad/sec
𝜋
θ2 =190*180 = 3.32rad/sec
We know that mass of belt per length =A*x*𝜌 whrer ,
A - cross sectional area of belt = bt =32 mm*19 mm= 608 mm 2 =608*10−6 𝑚2
=608*10−6 𝑚2 × 0.8𝑚 *1140kg/m3

= 0.554 kg/m
Therefore centrifugal tension , T c =mv2,

0.554 kg/m *(3m/sec)2 =4.35 N.
the maximum tension in the belt(T) , T=σ*A Where σ; normal stress
A; cross sectional area
From recommended value of σ =2*10 N/m then T = 2*10-6 N/m2*608*10-6 m2 =3040 N
-6 2
Let T1 = Tension in the tight side of the belt

T2 =Tension in the slack side of the belt
T1 = T-T c ,3040- 4.35N =3035.6 N
𝑇1
We know that 2.3log𝑇2 =𝜇𝜃 csc 𝛽
Where 𝜇 =cofficent of friction
𝛽 = 𝑓𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑔𝑟𝑜𝑜𝑣𝑒
𝜃 =angle of lag
KIOT PAGE 30
42.6
𝜇 = 0.54 − 152+2.8 =0.25
𝑇1
Then 2.33log𝑇2 =0.25*3.32°*csc 36 = 3.32
𝑇1 3.32
log𝑇2 = = 1.4
2.3
𝑇1
= 𝑒 1.4
𝑇2
3040𝑁
= 1.4 = 𝑇2 = 718.9 𝑁
𝑒
The power transmitted for the belt
P = (T1-T2)V
=(3035.6 N-718.9 N)*3m/sec
= 6.95 K w
The length of belt
L= π(r1+r2) +2x +(r2-r1)2/x
= π(187.5+75) + 2*800+(187.5-75)2/800
= 2.25 m
3.13 Electrical Motor selection

Table 3.6 Recommended power range 1
To finding electrical power for the motor

Electrical power is the power required to be delivered by the battery to the motor in order to
drive of its efficiency.
Electrical >Mechanical due to the motor efficiency factor and all the friction factors so that, Electrical
=k* Mechanical assuming k = a rough estimate value from 1.1 to 1.3 so,
Electrical = 6.95K w×1.1
= 7.5 K w
KIOT PAGE 31
3.14 Bearing selection
After analyzing different types of bearing we have divided to select a ball bearing type.
during selection of bearing we have to select high carbon steel by considering the following
parameter
 basic dynamic load rating (c)

 basic static load rating(co)
 combined radial &trust load(p)
1. a basic rating (c)dynamic load
L=(c/p)3
where L=fatigue life expressed in millions of revolution
p=contact applied load
c= basic dynamic load rating
2.basic static load rating(co)
3. combined radial &trust load(p)
In both radial &trust load are applied to a bearing, an equivalent load
p=x∗ Fr +y F a
where
p=equivalent load
x =a radial factor
v =a rotational factor radial
Fr=applied constant radial load
F a=applied constant thrust load
Y = thrust factor
For the rotation factor V is 1 for bearing with rotating inner ring starting from the
shaft diameter (d) = 50 mm by considering these the clearance for lubrication to be
around 1 mm. Therefore ,the bore diameter of the bearing will be
d bearing = d shaft +2(clearance)
So, d bearing =50 mm+2*1 mm =52 mm
By using this diameter it select the standard ball bearing type from table
 Bearing type =6312
 Standard ball =60 mm to 31mm
 standard width of bearing
 Dynamic load rating(C) =14000 lb
 Static load rating(Co) =10800 lb
From previous calculation in shaft design ,F vertical =3790 N =852 lb
KIOT PAGE 32
Fvertical 852 lb
To calculate the ratio = = 10800 𝑙𝑏 =0.078 and taking this appendixes to find
𝐶𝑜
𝐹𝑎
the corresponding value of C =0.26 ,V= 1 . by forming the ratio 𝑉 𝐹𝑟
but Fr =T/r = 559Nm /0.0175 = 2980 N=970 Lb

F ver/V Fr=852./970lb =0.1456<0.26=e
our bearing is double row type from appendix double bearing
x=1,y=0
and the equivalent load
p=xv Fr +y Fa
=(1)(1)(970 lb+0)
=970 lb
therefore the fatigue life will be
𝑐
L=(𝑝 )3
𝑙𝑏
= (14000 970𝑙𝑏 )3 = 3 ∗ 106 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛
hence ,the fatigue life bearing is approximately (3*106) revolution
3.15 Sieve
The sieves are one parts of the dry coffee processing machine that is used to carry the
coffee bean and the coffee husk ,when the coffee cherry can be hulled at the drum of final
products to be found so, in addition to sieves are the most important to differentiate the coffee
bean from the coffee husk because by means of sieve it is not stationery it is vibrate due to the
cause of vibration.
Many natural and manufactured materials occur in a disperse form, which means that they
consist of differently shaped and sized particles. The particle size distribution, i.e. the number
of particles of different sizes, is responsible for important physical and chemical properties
such as:
• mechanical bulk behavior

• surface reaction
• taste
• miscibility
• filtration properties
• conductivity
KIOT PAGE 33
This list could be continued at great length. The examples clearly show how important it
is to have a knowledge of the particle distribution, particularly within the context of
quality assurance in the production of bulk goods. If the particle distribution changes
during the manufacturing process then the quality of the finished product will also
change. Only a continuous monitoring of the particle size distribution can guarantee a
constant product quality.
By consideration of sieve work ,to select aluminum material . it have light weight and non
corrosive material. t= 7 mm , where t - thickness
Density of aluminum = 2.7*103 kg/m3
Volume of sieve = V = l*w t,
Where
l -length
t- thickness of sieve
w- width of sieve
V = 340× 220 ∗ 8 𝑚𝑚 = 5.984 ∗ 10−4 𝑚3
3
𝑚
𝜌= 𝑣
2700𝐾𝑔
=, 𝑚 = 𝜌𝑣 = 3
∗ 5.984 ∗ 10−4 𝑚3 = 1.618𝑘𝑔
𝑚
The down warred load applied on the shaft
1. weight of sieve = mg =16 .2 N
2.Weight of coffee bean =0.6048 N
3 .weigh of other material =0.4 N
Therefore the total load apply on the sieve shaft = 16.2+ 0.6048+0.4 =17.3 N
KIOT PAGE 34
3.15.1 Design of sieve shaft
Fig:3.17 Forces applied on sieve

∑Fy = 0, RA+RD =RB+RC--------------------------------(1)
+ RA +RD =8.65 +8.65 N= 17.3 N
∑MA =0, 8.65 N*0.04m +8.65 N*0.34 Nm= 0.38RD
= 0.38RD =2.9392
RD =8.65 N----------------------------------(2)
By substitution equation (2) in equation(1)
RA = 8.65 N
by section x-x
Mx = x*RA, let x = 39.95 mm =40 mm

Mx = 8.65N *0.04 m
= 0.548 Nm
by using section y-y
KIOT PAGE 35
My = RA*X +0.04 RB - RB*X

= 0.34*8.65 +0.04 *8.65 -8.65*0.34
= 0.348 Nm
Fig:3.18 bending moment diagram

From the bending moment diagram we can see that the bending moment is maximum at the
shaft B and C
Mmax = 0.348 Nm
As we know that the torque transmitted by the sieve shaft is
𝑃∗60
T= P*60 2𝜋𝑁 = 501 𝑁𝑚
We know that the equivalent twisting moment
Te = 𝐾𝑚 ∗ 𝑀 2 + (𝐾𝑡 ∗ 𝑇)2
= 1.5 ∗ 0.348 2 + (1 ∗ 501)2 = 501 Nm

We also know the equivalent twisting moment are
KIOT PAGE 36
π∗τ∗d3
Te= 16
From the above T =501 Nm
π∗τ∗d3
501Nm = 16
= 42 𝑀𝑝𝑎 ∗ 𝜋 ∗ d3 = 16 ∗ 501Nm
d = 40 mm
3.15.2 Design of helical spring

Aspiring is an elastic object used to study mechanical energy .spring are elastic bodies
(generally) metal that can be twisted ,pulled or compressed by some force. they can be return
to the original shape when the force is released.
The various important applications of springs are as follows :
 To cushion, absorb or control energy due to either shock or vibration as in car springs,
railway buffers, air-craft landing gears, shock absorbers and vibration dampers.
 To apply forces, as in brakes, clutches and spring loaded valves.
 To control motion by maintaining contact between two elements as in cams and
followers.
 To measure forces, as in spring balances and engine indicators
 To store energy, as in watches, toys, etc
Fig. 3.19 helical spring 1

Lo =free length of spring
d =diameter of spring wire
𝐷𝑖+𝐷𝑜
D =mean diameter of coil = D = 2
p =pitch space between coils
Di = inner diameter of coil
Do =outer diameter of coil
KIOT PAGE 37
F = load
𝐷
C = spring index = 𝑑 =mean coil diameter/ wire diameter
There is an important parameter in spring design called spring index.
The design of helical compression spring involves the following consideration
 Modes of loading :static load or alternating load
 The force deflection characteristic requirement for the given application
 Is there any space restriction
 Required life for springs subjected to alternating loads
 Environmental condition such as corrosive atmosphere and temperature
 economy desired
Considering these factors the designer select the material and specify the wire size
,spring diameter ,number of turns ,surface length and surface condition.
Design procedure for helical compression spring of circular cross section.
From data hand book select standard diameter

d= 4.115mmof wire (diameter of wire) and C =5
8𝐹𝐷𝐾
1. τ max = but, C =D/d ,D= Cd
𝜋𝑑 3
4𝐶−1 0.615 19 0.615
Since k =4𝐶−4 + = + , K =1.34125
𝐶 16 5
8∗8.65∗5∗4.15 𝑚𝑚 ∗1.34125
Then τ max = =35.897*103 N/mm2
𝜋∗(4.15 𝑚𝑚 )3
2. Mean diameter of coil (D)
Therefore, D = C*d = 5× 4.15𝑚𝑚 = 20.46 𝑚𝑚
Do = D +d = 20.46mm+4.15mm = 24.575 mm
Di = D-d =20.46mm - 4.15 mm = 16.345 mm
3. Number of coil or turns (i) =6
8𝑖𝐹𝐷 3 8∗8.65∗6∗( 20.46𝑚𝑚 )3
Y = = = 15.5mm
𝐺𝑑 4 800𝑀𝑝𝑎 (4.15 𝑚𝑚 )4
Table 3.7 Recommended table of helical 1
4.Free length Lo = (i+n)d +y +a where ,a= clearance 25% of maximum defliction

y =15.5 mm ,a=y/4 =15.5 mm/4 =3.875mm
i = square end , n = solid length =2
So , Lo = (6+2)*4.15mm+15.5 mm+3.275mm =52.3mm
KIOT PAGE 38
5. Stiffness or rate spring (k) , k =F/y 8.65N/15.5mm =0.558N/mm
𝐿𝑜−2𝑑 52.3 𝑚𝑚 −2∗4.15 𝑚𝑚
6. Pitch length (p) , p = = = 7.344 𝑚𝑚
𝑖 6
Solid length. When the compression spring is compressed until the coils come in contact with
each other, then the spring is said to be solid. The solid length of a spring is the product of
total number of coils and the diameter of the wire. Mathematically,
Solid length of the spring,
Ls = n'.d
where n' = Total number of coils, and
d = Diameter of the wire.
Free length. The free length of a compression spring, as shown in Fig. 23.6, is the length of
the spring in the free or unloaded condition. It is equal to the solid length plus the maximum
deflection or compression of the spring and the clearance between the adjacent coils (when
fully compressed). Mathematically,
Free length of the spring,
LF= Solid length + Maximum compression + Clearance between adjacent coils
(or clash allowance)
= 𝑛, × 𝑑 + 𝛿 max +0.15𝛿𝑚𝑎𝑥
The following relation may also be used to find the free length of the spring, i.e.
LF == 𝑛, × 𝑑 + 𝛿 max +(𝑛′ – 1) × 1 mm
In this expression, the clearance between the two adjacent coils is taken as 1 mm.
Spring index. The spring index is defined as the ratio of the mean diameter of the coil to the
diameter of the wire. Mathematically,
Spring index, C = D / d
where D = Mean diameter of the coil, and
d = Diameter of the wire.
Spring rate . The spring rate (or stiffness or spring constant) is defined as the load required
per unit deflection of the spring. Mathematically,
Spring rate, k = W / d
where W = Load, and
d = Deflection of the spring.
In actual practice, the compression springs are seldom designed to close up under the
maximum working load and for this purpose a clearance (or clash allowance) is provided
between the adjacent coils to prevent closing of the coils during service. It may be taken as 15
per cent of the maximum deflection.
3.15.3 Cam Design

A cam is a rotating machine element which gives reciprocating or oscillating motion to
another element known as follower. The cam and the follower have a line contact and
KIOT PAGE 39
constitute a higher pair. The cams are usually rotated at uniform speed by a shaft, but the
follower motion is predetermined and will be according to the shape of the cam.
The cam and follower is one of the simplest as well as one of the most important mechanisms
found in modern machinery today. The cams are widely used for operating the inlet and
exhaust valves of internal combustion engines, automatic attachment of machineries, paper
cutting machines, spinning and weaving textile machineries, feed mechanism of automatic
lathes etc.
Fig .3.20. cam and follower 10
In all cases, the follower must be constrained to follow the cam. This may be done by springs,
gravity or hydraulic means. In some types of cams, the follower may ride in a groove.
There are many types of follower from these it select flat faced follower.
There are two types of cams based on shape
1. Radial or disc cam: In radial cams, the follower reciprocates or oscillates in a direction
perpendicular to the cam axis.
2.Cylindrical cam. In cylindrical cams, the follower reciprocates or oscillates in a direction
parallel to the cam axis. The follower rides in a groove at its cylindrical surface. A cylindrical
grooved cam with a reciprocating and an oscillating follower .
Nomenclature of radial cams
Assumptions in flat faced cam design to select low carbon steel due to the manufacturing
process.
To construct the displacement diagram ,velocity and acceleration.
out ward = 120° Stroke = 15 mm
15𝑚𝑚
Dwell = 30 Minimum radius of cam = = 7.5 𝑚𝑚
2
Inward = 120° Dwell = 90° Shaft diameter = 30 mm
The displacement diagram is drawn as follows
1. Draw a semi-circle on the follower stroke as diameter.
2.Divide the semi-circle into any number of even equal parts (say eight).
KIOT PAGE 40
3.Divide the angular displacements of the cam during out stroke and return stroke into the
same number of equal parts.
4.The displacement diagram is obtained by projecting the points.
Since the follower moves outward and in ward with simple harmonic motion .therefore the
displacement diagram as shown below
Fig :3.21 Dimension of cam
3.15.4 Welding process

A welded joint is a permanent joint which is obtained by the fusion of the edges of the two
parts to be joined together, with or without the application of pressure and a filler material.
The heat required for the fusion of the material may be obtained by burning of gas (in case of
gas welding) or by an electric arc (in case of electric arc welding). The latter method is
extensively used because of greater speed of welding.
Welding is extensively used in fabrication as an alternative method for casting or forging and
as a replacement for bolted and riveted joints. It is also used as a repair medium e.g. to reunite
metal at a crack, to build up a small part that has broken off such as gear tooth or to repair a
worn surface such as a bearing surface.
The main considerations involved in the selection of weld type are:
 The shape of the welded component required,
 The thickness of the plates to be welded, and
 The direction of the forces applied.
KIOT PAGE 41
Basic welding symbols
The basic weld symbols according to IS : 813 – 1961 (Reaffirmed 1991

Table :3.8 symbol of welding 1
Design of welding
Fig:3.22 welding.
From the above calculation of forces applied on the frame is known so, p=841.5N
From the recommended table permissible shear stress (τ max =250 M pa) hence,
L = 40 mm b =60 mm e = 360 mm
Let size of weld and t = throat thickness
KIOT PAGE 42
The joint is subjected to direct shear stress and bending stress , we know that the throat
area of rectangular fillet weld.
A =t(2b+2L) =0.707s(2b+2L) but t= 0.707s it is recommended value of t
=0.707s(2× 60 + 2 × 40) = 141.5𝑠 𝑚𝑚2
𝑝 841.5 𝑁 5.95 𝑁
Therefore ,direct shear stress (τ) = 𝐴 = 141.4 𝑆 𝑚𝑚 2 = 𝑆 𝑚𝑚 2
We know that bending moment M = P× 𝑒 = 841.5𝑁 × 360 𝑚𝑚 = 3.02 × 105 𝑁𝑚𝑚
From table we find that for a rectangular section ,section modules,
60 2
Z = t(b L+𝑏 2 /3) = 0.707𝑠(60 ∗ 40 + = 2545.2𝑠 𝑚𝑚2
3
𝑀 3.02∗10 5 𝑁𝑚𝑚 118.65
Therefore bending stress 𝛿𝑏 = = = = 𝑁/ 𝑚𝑚2
𝑍 2545 .2 𝑠 𝑚𝑚 2 𝑠
From the above given from ASTM A36( low carbon steel) the recommended value of
𝑠𝑕𝑒𝑎𝑟 max.so, τ max = 250Mpa
τ max =1/2 √ 𝛿𝑏 2 + 4𝜏 2
118.65 2 5.95 2 59.6
= 250 =1/2 ( ) + 4( ) =
𝑠 𝑠 𝑠
= 250 s = 59.6
s= 0.2385 mm
Again the second bar is in the following way to be calculated for the welding process so to
calculate these welding process to follow the same step to the previous above calculation.
On these bar the applied load must be p= 1.08kN and the same allowable shear stress are
(τma) = 250Mpa
L =40 mm b = 60 mm e =280 mm
Let(s) size of weld and t = throat thickness

The joint is subjected to direct shear stress and bending stress , we know that the throat area of
rectangular fillet weld.
A =t(2b+2L) =0.707s(2b+2L) but t= 0.707s it is recommended value of t
=0.707s(2× 60 + 2 × 40) = 141.5𝑠 𝑚𝑚2 therefore direct shear stress,
𝑃 1.08𝐾𝑁 7.637
𝜏= = = 𝑁/ 𝑚𝑚2
𝐴 141.4 𝑠 𝑚𝑚 2 𝑆
We know that bending moment M = P× 𝑒 = 1.08 𝐾𝑁 ∗ 280 𝑚𝑚 = 3.02 × 105 𝑁𝑚𝑚
From table we find that for a rectangular section ,section modules,
KIOT PAGE 43
60 2
Z = t(b L+𝑏 2 /3) = 0.707𝑠(60 ∗ 40 + = 2545.2𝑠 𝑚𝑚2
3
𝑀 3.02∗10 5 𝑁𝑚𝑚 118.65
Therefore bending stress 𝛿𝑏 = = = = 𝑁/ 𝑚𝑚2
𝑍 2545 .2 𝑠 𝑚𝑚 2 𝑠
From the above given from ASTM A36( low carbon steel) the recommended value of
𝑠𝑕𝑒𝑎𝑟 max.so, τ max = 250Mpa
τ max =1/2 √ 𝛿𝑏 2 + 4𝜏 2
118.65 2 7.637 2
= 250 =1/2 ( ) + 4( ) . 𝑠 = 0.239𝑚𝑚 ,
𝑠 𝑠
3.16 Selection Of Fan

To select the blower we consider the mass of coffee cherry ,the weight of the coffee and the
weight of coffee husk because to consider these when the blower(fan) to know to require the
coffee husk remove easily and simply to be avoided by using the penetrations of the wind
pressure. So ,it must be calculated the following things.
The mass of coffee cherry= mass of coffee bean + mass of coffee husk but the mass of coffee
cherry can be known from the previous calculation (0.38 g)
0.38g = 0.28 g +mass of coffee husk(m h)
m h = 0.38 g -0.28 g = 0.02g
The weight of coffee bean = mg ,where m =mass of coffee, g= gravity
= 0.28× 10−3 𝑘𝑔 × 10𝑚/ sec = 2.8 × 10−3 𝑘𝑔 𝑚/𝑠𝑒𝑐 = 2.8 × 10−3 𝑁
The weight of one coffee husk = m h g where m h = mass of coffee husk, g= gravity
0.02× 10−3 𝑘𝑔 × 10𝑚/ sec = 0.2 × 10−3 𝑘𝑔 𝑚/𝑠𝑒𝑐 = 0.2 × 10−3 𝑁
The weight of one coffee cherry = 0.3× 10−3 𝑘𝑔 × 10𝑚/ sec = 0. 3 × 10−3 𝑁
The drum hulled the coffee at one time to be the total coffee cherry is 216 .from this the
coffee bean of mass are as follows
 Mass of coffee bean = 0.28g× 216 = 60.48 𝑔
 Mass of coffee husk =0.02 g× 216 = 4.32 𝑔
 Weight of coffee bean = 0.0648 kg × 10𝑚/ sec = 0.6048𝑁
 Weight of coffee husk bean = 0.00432kg
To purchase the fan (blower) first we consider the following items
 Coffee husk pressure
 Coffee bean pressure
 pressure required to move the coffee husk
 desired air flow rate( Q)
Size of diameter(225 mm)
KIOT PAGE 44
Table : 3.9 Recommended table of fan 9
Note: C fm = cubic feet per minute ,a measure air flow

Ps = static pressure ,resistance to air flow measured inches of water gauge
BHP = brake horse power ,a measure of power consumption used to
determine the proper motor horse power and waiving
HP = horse power used to indicate a fan's motor size
Rpm = revolution per minute ,measure of fan speed
From the previous calculation F cob = 0.6048 N , A= 225 mm× 70 𝑚𝑚 = 15750𝑚𝑚2
𝐹𝑐𝑜𝑏 0.6048 𝑁
Coffee bean pressure (p cob) = = 15750 𝑚𝑚 2 = 38.4𝑝𝑎
𝐴
𝐹𝑐𝑜 𝑕 0.0482 𝑁
Coffee husk pressure P coh = = 15750 𝑚𝑚 2 = 2.74 𝑃𝑎
𝐴
The fan generating pressure =31 pa from standard table
3.17 Frame
The frame is the structure unit which carries the main load . it ensures rigidity and stability of
the milling unit and serves as the base and support .
The frame was designed to holed other various machine components in the relative and stable
position for good operation.
3.18 Design Of Column

To design the column 1st it considered the following things .
The compression stress(𝛿𝑐) and normal stress.

all are in mm but height is in m
𝐹
𝛿 = 𝐴 , 𝑊𝑕𝑒𝑟𝑒 𝛿, 𝑛𝑜𝑟𝑚𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠, 𝐹 − 𝑎𝑝𝑝𝑙𝑖𝑒𝑑 𝑙𝑜𝑎𝑑, A - cross sectional area and t-
thickness of column=2 mm
𝑃
𝛿𝑐 = 𝑊𝑕𝑒𝑟𝑒, 𝐴𝑐 − 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛 𝑎𝑟𝑒𝑎, 𝛿𝑐 − 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛 𝑠𝑡𝑟𝑒𝑠𝑠
𝐴𝐶
A= L× 𝑤) − 𝐿 − 2𝑡 ∗ 𝑤 − 2𝑡
KIOT PAGE 45
= 40 ∗ 60 𝑚𝑚2 − 60 − 2 ∗ 6 ∗ 40 − 2 ∗ 6 = 2400𝑚𝑚2 − 1344𝑚𝑚2
= 1056𝑚𝑚2
Ac = L× 𝑊 = 1.2𝑚 ∗ 0.06𝑚 = 0.072𝑚2
𝐹 605.5𝑁
Then, 𝛿 = 𝐴 = 1056 𝑚𝑚 2 = 0.573 𝑀𝑝𝑎
𝑃
𝛿𝑐 = 𝐴𝐶 = 0.573 𝑀𝑝𝑎/0.072𝑚2 =7.965 M pa
By considerations of compression stress it select the steel material to resist this compression
force is ASTM A366(alloy1008 steel) its allowable stress is 180 Mpa ,then to calculate factor
of safety as follows
Factor of safety =
material yield stress 180𝑀𝑝 𝑎
= = 22.5 𝑠𝑜, 𝑜𝑢𝑟 𝑑𝑒𝑠𝑖𝑔𝑛 𝑜𝑓 𝑢𝑝 𝑟𝑖𝑔𝑕𝑡 𝑐𝑜𝑙𝑢𝑚𝑛 𝑖𝑡 𝑖𝑠 𝑚𝑜𝑟𝑒 𝑠𝑎𝑓𝑒
design of load 8𝑀𝑃𝑎
3.19 Design of beam

when the distributed load is applied on the beam is in the following figure
Fig:3.23 beam
By using section method x-x
Given
L =360 mm, w= 605.56N
∑FY =0 , RA +RB =218 N------------------------(1)
BY taking of the moment at A = 0 , ∑ MA = 0
218N × 0.18𝑚 = 𝑅𝐵 ∗ 0.36𝑚 -----------------(2)
218 N∗0.18 m
But, RB = = 109 𝑁 , by equating the equation 1 and 2
0.36 𝑚
RA +RB =218N , but RA =218- 109 = 109N
Bending moment diagram
By using section method x-x
Mx = RA× 𝑋 , 𝑙𝑒𝑡 𝑥 = 180 𝑚𝑚

Mx = 109N× 0.18 𝑚 = 19.62𝑁𝑚
KIOT PAGE 46
Fig:3.24 bending moment diagram
3.19.1 Checking Deflection On The Beam
Y = deflection
Fig:3.26 diagram of deflection
𝑊𝐿4
y= 384𝐸𝐼 , 𝑊𝑕𝑒𝑟𝑒 𝑙 = 𝑙𝑒𝑛𝑔𝑡𝑕 𝑜𝑓 𝑏𝑒𝑎𝑚 = 384𝑚𝑚,
𝐼 = 𝑚𝑜𝑚𝑒𝑛𝑡 𝑜𝑓 𝑖𝑛𝑒𝑟𝑡𝑖𝑎 𝑜𝑓 𝑡𝑕𝑒 𝑏𝑒𝑎𝑚
E= modulus of elasticity for steel alloy A2130 E =220Gpa W= weight
𝑏𝑑 3 0.04∗0.06 3
But I = = = 2.2 × 10−7 𝑚𝑚4 Therefore,
12 12
605.56(∗0.36)4
y = 384∗220∗10 9 ∗2.2∗10 −7 = 0.00000547 = 0, 𝑠𝑜 𝑡𝑕𝑒𝑟𝑒 𝑖𝑠 𝑛𝑜 𝑑𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛 𝑜𝑛 𝑡𝑕𝑒 𝑏𝑒𝑎𝑚
Table: 3.10 formulas of second moment inertia 8
KIOT PAGE 47
Cross- section Second moment of area I(𝑚4 )
Circular 𝜋D4/64
Hollow cylinder 𝝅(D4-d4)/64
square B4/12
Rectangular bd3/12
Triangular bh3/12
Semi-circular 0.007D4
Regular hexagon 0.06D4
3.20 Bolt and Nut Selection

It must be select nut and bolt by considering its function from standard dimensions of screw
threads, the reason that it must A machine element used for holding or joining two or more
parts of a machine or structure is knows a fastener. the fasteners are of two types, permanent
and removable. bolts and nuts in combination are used for fastening components that require
frequent assembly and disassembly. In this design bolt and nut in combination used to fit or
hold with casing to another casing, hopper to casing of another parts.
be select bolt and nut are because of bolt and nut are:
 available in mass on the market

 cheap in cost and
 available in different dimension and quality
Table: 3.11 dimension of bolt and nut 7
Designation Pitch in D of nut Dp of nut dB of bolt Dn of nut Quantity

mm and bolt in and bolt in in mm in mm
mm mm
M12 1.75 12 10.863 9.858 10.106 16
where ,
D=major or nominal diameter of nut and bolt
d p=pitch diameter of nut and bolt
dB=minor diameter of bolt
3 .21. Manufacturing Process Of Each Material

3.21.1 Manufacturing processed of spring
Making compression springs is a lot more fun than making either extension or torsion springs,
but it's also a lot more complicated.
Before we start, let's have a word about equipment. Compression springs have pitch -that's the
distance between the open coils in the spring and to make a spring with
pitch means that you have to be able to control how fast your wire guide travels from left to
right as the arbor turns around. With a lathe, it's easy.
KIOT PAGE 48
But with a drill or a hand winder, it's more difficult. Not impossible, just more difficult.
Spring shops get around the difficulty by buying a hand-winding machine designed for
making light compression springs. These are designed so that once you set it up, you can
make any number of springs and they will all be exactly the same
3.21.2 Manufacturing processes of shaft

 Cutting raw material
 turning first grinding
 turning second grinding
 profile - spherical
 heat treatment
 cylindrical grinding
 final inspection
3.21.3 Manufacturing processes of the hopper

1. Trace and cut the sheet metal according to the dimension .
By sheet metal cutting machine
2. Prepare four identical faces and bend the edges .
3. Connect the faces and weld them using arc welding technique
3.21.4 Manufacture of key:

Machining (shaper machine)
3.21.5 Manufacture of perforated cylinder

Sheet metal rolling rolling and punching
3.21.6 Manufacturing of pulley:

Sand mold casting
3.21.7 Manufacturing of sieve frame

Welding according to the dimension
3.21.8 Manufacture of frame

The main process is similar to any metal fabrication operation . It includes
cutting,bending,joining ,folding and grinding.
3.21.9 Manufacture of ball bearing

Turning operation
Center less grinding
heat treatment
Hardness testing
Rough grinding
KIOT PAGE 49
finish grinding
Honing and supper finishing
Washing
Application of rust preventive
Ready for dispatch assembly
3.21.10 Manufacturing process of threshing drum

 Cutting
 Welding
 drilling
 punching
3.22 Cost analysis of material

Table: 3.12 cost analysis of material
No Part name Quantity Material Estimated

Cost
(birr)
1 Electrical motor 1 - 5000
2 V-belt 2 Rubber 400

3 Pulley 7 Cast iron 5250
4 Shaft 2 Steel 500
5 Ball bearing 4 Steel 600
6 Parallel key 7 Steel 280
7 Helical spring 2 Low carbon 100

steel
8 Sieve 1 Aluminum 175
9 Perforated cylinder 1 Mild Steel 1000
10 Cover plate 1 Mild steel 250

11 Frame 4 Mild steel 320
12 Fan 1 - 1500
13 Hopper 1 Mild steel 250
14 Bolt 16 Cast iron 320

15 Nut 16 Cast iron 100
16 Column 8 Low carbon 160
Total cost stee 16205
KIOT PAGE 50
3.23 Maintenance of dry coffee processing machine
Table:3.13 Maintenance Schedule
No Material Daily Weakly Monthly 3 6 Yearly 2 Repair Replace

type Month Month yearly
1 Hopper  
Perforated  
2 cylinder
Threshing  
3 drum
4 Shaft  
5 Bearing  
6 Pulley  
7 V-belt  
8 Motor  
9 Sieve  
10 Spring  
11 Key  
Cam  
12 &flower
13 Fan  
14 Frame  
 
15 Bolt
Table: 3.14 check list of material `
No Material Check list of Maintenance

type
1 Hopper  Check carries of load
2 Perforated  Check wear of the groove
cylinder
3 Threshing  Check clearance between from concave to drum
drum  Check bulking of the hole
4 Shaft  Check :Deflection & wear
5  Faulty mounting(abrasive wear)
 Improper use of lubrication
Bearing  Contamination (corrosion)
 Miss alignment of the shaft on the pulley
KIOT PAGE 51
 In proper handling(load)
6  Belt tension on pulley
 Check motorized pulley free to rotate
Pulley  Surface coating
 Thermal protection
 Correctly connected to the power supply
7  Belt alignment on the pulley
 Tight side tension
V-belt  Slack side tension
8 Motor  Electrical installation

9  Clean the hole
Sieve  Check vibration
10 Spring  Check compression and extension values
11 Key  Check proper alignment of key with shaft
12 Cam  Check rotation
&flower  Check proper attachment of flower
13  Check generating pressure
Fan  Check rotating of blade
14  Check deflection
Frame  Check welding
15 Bolt  Check wear and corrosion
KIOT PAGE 52
CHAPTER FOUR
4. Conclusion
From the project we conclude that the two components of a dry coffee processing machine,
the threshing drum and the perforated cylinder are the most important parts and if they are
designed well, the whole process will become efficient.
The project also shows that it is possible to process a considerable amount of coffee with
limited space.
Provide new modified model of huller, with easy manufacturing process locally available.
The design includes material selection, mechanism design, dimensional analysis,
determining power requirement, strength analysis, vibration analysis, and 3D model
In our machine design it also includes maintenance schedule, cost analysis, to specify cause
of failures and manufacturing of parts.
To purchase fan and motor by considerations of the working capacity related to the machine.
WUKIOT Page 53
4.1 Recommendation
Finally we recommend that the project should be continued by other students and interested
designers so that it will be complete and very helpful for the countries growth.
Due to the cost of our design machine it can be easily manufactured and for the customer. so,
in our local countries their scarcity of dry coffee processing machine, but our design is more
essential to consider those problems it can be use and in lower cost and easily to operate the
machine.
In our country coffee is one of the most important to export in foreign country's but, there is
no quality coffee to export due to the problem of huller and sieve so, our design machine is
applicable for to minimize those problems
WUKIOT Page 54
4.2 Reference
1 R.S. KHURMI & J.K. GUPTA. A TEXT OF MACHINE DESIGN, Eurasia
publishing house (p v t.) ltd RAM NAGAR, NEW DELHI-110 055 2005 [p545-555,
730-740, 1030-1045]
2 Shigley’s Mechanical Engineering Design, Eighth Edition McGraw_-Hill[p118,558,1141]
3 http://www.coffeeresearch.org/coffee/varietals.htm
4 http://www.conveyusa.com
5 Standards for electric motors (P d f). http://www.google.com
6 Fundamental of machine component design 3rd edition ,Robert C.juvinal,(Kurt
M) 186,489,790
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WUKIOT Page 55

Dry Coffee Processing Machine

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DESIGN OF DRY COFFEE PROCESSING MACHINE 2015

BESUFEKAD ESTIFANOS,HABTAMU G/ MARIAM,HUSSEN ALI AND WUDEST

ITR/0228/03, IRT/480/03 ,ITR/535/03 ,ITR/986/03 RESPECTIVELY.

BSC MECHANICAL ENGINEERING

KOMBOLCHA INSTITUTE OF TECHNOLOGY, 2015 E.C

KIOT PAGE iii

Table of Contents page

KIOT PAGE iii

Fig 2.1 This Old-Fashioned Hulling Machine Is Operated by Ox Power in Venezuela------6

Fig: 2.1 This Old-Fashioned Hulling Machine Is Operated by Ox Power in Venezuela------6

Fig; 2.3 Hand-power double-disks pulpier-----------------------------------------------------------9

Fig 2.4 Group of English cylinder coffee-pulping machine--------------------------------------9

Fig 2. 5 Spectrum industries--------------------------------------------------------------------------10

Fig 2. 6 Marshall fowler------------------------------------------------------------------------------10

Fig 2.7 v-mac industries------------------------------------------------------------------------------11

Fig 3.measurment of coffee---------------------------------------------------------------------------13

Fig 3.1 dimensions of coffee -------------------------------------------------------------------------13

Fig 3.2 rotating cylinder with perforated----------------------------------------------------------14

Fig 3.3 hopper------------------------------------------------------------------------------------------15

Fig:3.4 Geometrical analaysis of hopper-----------------------------------------------------------15

Fig 3.5 Threshing drum -------------------------------------------------------------------------------16

Fig 3.6 perforated cylinder----------------------------------------------------------------------------17

Fig 3.7 cross section of coffee huller ----------------------------------------------------------------17

Fig.3.8 shear force analysis of perforated cylinder-------------------------------------------------18

Fig,3.9 force acting on the perforated cylinder-----------------------------------------------------18

Fig 3.10 pulley diamention---------------------------------------------------------------------------21

Fig :3.11 dimension of pulley on motor--------------------------------------------------------------22

Fig:3.12 belt --------------------------------------------------------------------------------------------23

KIOT PAGE vii

Table:3.4 Recommended value for Km and kt ------------------------------------------------------28

Table3.6 Recommended power range-----------------------------------------------------------------31

Table: 3.10 formulas of second moment inertia----------------------------------------------------48

Table: 3.12 check list of material----------------------------------------------------------------------51

KIOT PAGE viii

1.2 Objective Of The Project

1.2.2 Specific Objective

1.3.1 Benefiters of Dry Coffee Huller Machine

1.4 Scope of The Project

2.1 General Description of Coffee Plan

2.1.1 Types of Coffee Bean Plants

Fig 2. Coffee bean plant 11

2.1.2 The Kona

2.1.3 The Arabica

2.1.4 The Robusta

2.2 Traditional Coffee Huller Machine

Fig :2.1 This Old-Fashioned Hulling Machine Is Operated by Ox Power in Venezuela 3

2.3 Development of Plantation Machinery

Fig 2.2 Walker's Original Disk Pulpier, 1860

Fig ;2.3 Hand-power double-disk pulpier 4

Fig 2.4 Group of English cylinder coffee-pulping machines 4

2.4 Spectrum Coffee Huller

Fig 2. 5 Spectrum industries 3

2.5 Cross Beat Coffee Huller

Fig 2. 6 Marshall fowler 3

2.6 Coffee Huller

Fig 2.7 v-mac industries 3

3.2 Dimensions of coffee bean

Fig 3.measurement of coffee

Fig 3.1 dimensions of coffee

Illustration of measuring sides for coffee beans

 Mean weight of coffee cherry  0.3g

Fig 3.2 rotating cylinder with perforated 3

3.3 Design of hopper

Fig 3.3 hopper

length of the arc (A)=n2πr/360°,therfore 50113.752π/360°=99.26mm and

=60810−6 𝑚2 × 0.8𝑚 1140kg/m3

My = RAX +0.04 RB - RBX