Threshing Cylinder Design Equations

Consider the stationary thresher show in the figure below. To determine the forces
imposed on the threshing cylinder, an estimation of feeding rate is needed. The highest
mean yield (t/ha) in a given locality has to be known. The feed rate can be calculated as
follows:

Y ×V ×w×e
Q=
36 ……………………. (1)

where:

Q = feeding rate, kg/s,

Y = yield, tons/ha,
V = forward speed of combine, km/h,
W = width of cut of combine, m
e = field efficiency,%

The force ‘F’ required to thresh is a function of cylinder linear speed as well as the
friction coefficients between the crop-crop and crop-metal.

Thus,
F=F c + F r ………..……………….......... (2)

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 where:

F = the force needed for threshing the crop, N

Fc = impact force of the cylinder, N,

Fr = friction force, N

The impact force Fc may be calculated from Eq. (3) below;

F c=Q ( V 2−V 1 )
……………………………. (3)
where:

V2 = speed of the threshed crop as it exits from the threshing chamber; m/s

V1= speed of the crop as it enters the threshing unit (elevator speed, m/s)

V2 is proportional to the linear speed of the cylinder (V) and given below as:

V 2 =aV ……………………………………… (4)

2 πN
where V =Rω=r
60

r = threshing cylinder radius,

ω = cylinder rotary speed, rad/s,

N = cylinder speed in rev/min;

a = a coefficient, an empirical figure that depends on cylinder length, straw

moisture, shape of rasp bar, feed rate and physical properties of the threshing
unit.

For a cylinder with a length of 0.8 m, with crop having moisture content is between 15
and 25%, feed rate is 3.50 kg/s, the coefficient, a, can be between 0.70 and 0.85.
The linear speed of the cylinder ‘V’ can also be determined from values recommended
for specific type of crop.

Inserting Eq. (4) in Eq. (3):

F c=Q ( aV −V 1 )
…………………………………… (5)

Fr is dependent on many factors such as the coefficient of friction, manner of breaking

the straw, the intensity of threshing, etc. It is, however, proportional to the total force
necessary to thresh the crop, F. Hence, Fr can be given as:

F r =fF …………………………………..…….. (6)

Using Eqs (5) and (6), Eq. (2) can be written as:

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 F=Q ( aV −V 1 ) + fF
……………….…..…….. (7)

Or,

F ( 1−f ) =Q ( aV −V 1 )

and therefore,

Q ( aV −V 1 )
F=
1−f ……………………………………. (8).

The required power to thresh, P1 in watts, can be obtained by multiplying the force, F,
Eq. (8) by V;
Q ( aV −V 1 )
P1 =FV = V
( 1−f ) ……………………………... (9)

The coefficient f, for rasp bar type cylinders is between 0.65 and 0.75 and for
finger/spick tooth type is between 0.70 and 0.80.

The total power for threshing is more than what is give in Eq. (9). Power is also needed
to overcome the air resistance against the rotation of the cylinder and the friction force
in bearings. This power can be calculated using Eq. (10) below:

P2 =AV +BV 3 ………………………………….. (10)

The first term, AV, is due to friction and the second term, BV 3 , is due to air resistance. A
and B are two coefficients. Coefficient A is between 0.85 - 0.90 N per 100 kg mass of
rasp bar type thresher cylinder and 5 - 5.5 N per 100 kg mass of finger types.
Coefficient B for cylinder diameters of 550 mm is equal to 0.065 N.s 2/m2 per meter of
cylinder length for rasp bar type cylinder and 0.045 N.s 2/m2 per meter of cylinder length
for finger type.

The total required power is then:

Q ( aV + V 1 )
P=P1 + P2 = V + AV + BV 3
( 1−f ) ……………… (11)

Please note that the equation above can used to estimate the toque on the cylinder
shaft provided that the angular velocity of the cylinder in rad/s is known; i.e.

Power , P=T ×ω ,

where P= power in kWatts , T = Torque in in kN , ω=angluar peed in rad/s

The diameter of cylinder shaft can be calculated from the following classic equation.

3
 √[ ]
2
16 α×F×d o ( 1+k 2 )
d o= C m×M + + ( Ct T ) 2
πτ ( 1−k ) 8
4

… (12)

where,
do = tube outside diameter, mm
K = do/di
di = tube inside diameter, mm
M = bending moment, N.mm
 = permissible shear stress, N/mm2
T = torsion moment, N.mm
Cm, Ct = coefficients
To calculate the moments, the imposed forces must first be determined as follows:

1. Horizontal forces, which are reaction to the threshing force and friction, may be
calculated from the total power requirement.

2. Vertical forces due to the weight of the components such as: rasp bars, plates,
star flanges, tube flanges, tube, power transmission pulley, shaft flanges, short
and long shafts.

The weight of the cylinder should be known. Power is transmitted to the cylinder by V-
belt pulleys at an angle of 30° with respect to the horizontal in most cases. The tight
and slack side tensions can be calculated from the following equation;

( T 1 +T 2 )
P= V
1000 ………………………………… (14)

Where,

P = total design power

T1, T2 = tensions on the tight side and slack side of the V-belt, N,
V = linear speed of the belt, m/s
T = Torque, N-m,
N = rotational speed, rpm

Belt Drive Analysis at Low Speed

The maximum torque that can be transmitted between the belt and the pulley occurs
when limiting friction is developed around the arc of contact.

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The centrifugal forces acting on a short length of the belt which subtends an angle of
at the centre of the pulley is:
2 v2
F c=mω r=m
r

Please note that in this case either the mass of the belt which subtends an angle
or the velocity at which the belt is traveling is small to account for centrifugal force.

where:

Fc = centrifugal force,

m = mass in kilogram,

 = angular velocity of one of the pulleys under consideration,

r = radius of one of the pulleys under consideration

Allowance for Centrifugal Force

The analysis above assumes, in effect, that the belt and pulley is at rest. In practice
this is not often the case and the belt is subjected to a centrifugal force as it passes
round the pulley. If the mass of the belt per unit length is m and its speed is v, the
centrifugal force, F, acting on an element subtending an angle  (see figure below):

v2
mrd θ =mv 2 dθ
r

If Tc is the tension in the belt due to this centrifugal force, then, resolving forces on
the element radially:

dθ
mv 2 dθ=2T c
2
Or

2 g( )
dθ wv 2
2 T c×sin = dθ

1 δθ
As δθ →0 , sin δθ →
2 2

wV 2
T c=
 g

where w = weight of belt per unit length

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If the belt is transmitting power, let T1 and T2 be the total tight and slack side tension
respectively when slipping is about to occur and  be the angle of lap (see figure
below).

The element subtending an angle  is subjected to tensions T and T+T at its two
ends and also to the reaction, R, between the belt and pulley and centrifugal force, F.

Resolving forces radially:

dθ dθ
( T + dT ) sin +T sin =R+ F=R+ mv 2 dθ
2 2

1 δθ
As δθ →0 , sin δθ →
2 2

( 2
)
Therefore, R= T −mv dθ=( T −T c ) dθ
Resolving forces tangentially:

dθ dθ
( T + dT ) cos−T cos =Rμ
2 2
dθ
cos
As   0, 2 1

Therefore, the equation above reduces to,

dT =μR

From radial and tangential resolution of forces and state equilibrium we have that:

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 R=( T −T c ) dθ
and dT =μR

From which one can write the deferential equation:

dT
=( T −T c ) dθ
μ

dT
=μdθ
( T −T c ) Therefore,
T1 dT θ
∫2 T −T c
=∫0 μdθ

ln ( T −T c ) =μθ

Note that T values are between T1 and T2; but T1 > T2.

From which
T 1 −T c
=e μθ
T 2 −T c

T1 – Tc and T2 – Tc are the effective driving tensions.

If the diameters of the driving and driven pulleys are unequal, the belt will slip first on
the pulley having the smaller angle of lap, i.e. on the smaller pulley.

The power transmitted = (

T 1 −T 2 ) v

= [(
T 1 −T c ) −( T 2−T C ) ] v

T 1 −T c
T 2−T c =
But, e θμ , hence, power, P, can be written as :

[
P= ( T 1−T c ) −
(( T 1 −T c )
e
μθ )] v

=
[
P= ( T 1−T c ) 1−
( 1
e μθ )] v=
For given value of T1, , and , the velocity at which the power transmitted is a
maximum is given by:

dP d
dv dv 1 e
1
= ( T −T c ) 1− μθ
( )
Since
( 1−
e ) is constant, P is maximum when
1
μθ
d
( T −T ) v=0
dv 1 c
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 d d
T =mv 2 ( T 1 −mv 2 ) v =0 ( T 1 v−mv 3 )=0
Since c , then dv  dv
2
Therefore, T 1−3 mv =0 and the optimum velocity for maximum power can be
calculated as follows.

v=
√ T1
3m

The maximum power is then obtained by substituting this value of T c and the
corresponding value of v in equation above. If the mass or velocity of the belt is
negligible, the following equations must be used.

T1
T2
=e μθ
and
Power=T 1 1−
( 1
e μθ )
V-Belt or Rope Drive

Although rope can be used for such drives, the vast majority rely on V-belts. In many
applications the pulley has more than one groove and there are obviously an
appropriate number of belts.

For a v-grooved pulley, the normal force between the belt or rope and the pulley is
increased since the radial component of this force must equal R. thus, if the semi
angle of the grove is β, figure below

R=2 N sin β

μR μ
μ2N= =μ' R μ '=
But friction force = sin β , where sin β

The analysis now becomes similar to that of a flat pulley where the equivalent
coefficient of friction is. The power transmitter is given by the equation:

( )
1
Power=( T 1−T c ) 1− μθ
v
sin β
e

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Initial Tension

The belt is assembled with an initial tension, T o. When power is being transmitted, the
tension in the tight side increases from T o to T1 while on the slack side decreases from
To to T2. If the belt obeys Hooke’s law and its length to remain constant, the increase in
length of the tight side is equal to decrease in length in the slack side, i.e.
T 1−T o =T o −T 2 since the length and cross-sectional areas of the belt are the same on
each side.
Hence
T 1 +T 2=2 T o

Belt Length and Lap angle

Length of Belt (open, not crossed), L is given by the equation:

π ( d 1 −d 2 ) 2
2 ( 1 2)
L=2 C+ d +d +
4C

where d1 & d2 = diameters of pulleys, C = pulleys center distance

Length of Belt (closed, belt crossed), L is given by the equation:

π ( d 1 + d 2 )2
L=2 C+ ( d 1 +d 2 ) +
2 4C

Cleaning Mechanism

Critical velocity Determination

The behavior of particles in an air stream is governed by their aerodynamic properties.

Let particles behavior considered in vertical stream.

Parameters are:

 Vcr = critical velocity, m/s

 K = coefficient of resistance of air ( k depends on shape of kernel, kernel’s

projected surface, state of medium in which the kernel moves and on the
velocity of air stream and decreases with an increase in air velocity)

 kd = drift coefficient

 G = gravitational force=weight of body (grain), N

 R = upward force due to air stream, lift by air stream, N

 ρa = density of air, kg/m3

 A = projected area of body on a plane perpendicular to air stream direction, m2

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  Va = velocity of air stream in vertical direction, m/s

 U = velocity of the kernel (grain), m/s

Using Newton’s law;

R=kρa A ( V a −U )2 N s
……………………………………… (1)

During air flow in vertical direction, forces G (gravitational force) and R (drag force) in
opposite direction:

 If G > R the particle moves downward

 If R > G the particle moves upward

 If G = R, that is U = 0, then V a = Vcr = critical velocity (terminal velocity), m/s, the

particle is suspended in air.

At G=R , V cr =
√ G
k ×ρa × A ……………………………….. (2)

Or

G=k×ρ a ×A×V 2cr ………………………………….……….. (3)

9 . 81×k ×ρa × A
The drift coefficien , k d =
G …………………….. (4)

Inserting equation ( 3 ) in equation (4 ),

9 . 81×k ×ρa A 9 . 81
k d= =
k ×ρa × A×V 2cr V 2cr …………………….… (5)

Coefficients k and kd are difficult to determine are therefore determined experimentally.

The Vcris is determined using critical velocity determination apparatus with transparent
vertical tube. The Vcris sometimes determined from the dynamic head (N/m 2) of the air
stream. Since the dynamic head of air (N/m 2) stream equals to the kinetic energy of a
unit volume of air i.e.
mV a2 ρa V 2a
h a= = , N / m2
2 2 ……………..………………….. (6)

Or

V a=
√ 2
h
g d ………………………………………………… (7)

where
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M = ρa, mass of a m3 of air

Assume, at temperature of 20OC and 10.3x104 N/m2 atmospheric pressure, the air
density ρa=1.20 kg/m3, then,

V a=
√ 2.
h =1 .28 √ hd , m/ s
1. 20 d …………………………………….. (8)

The dynamic head of air is determined by pilot tube. Knowing the V cr the coefficients k
and kd can be determined easily from equations 2 and 4, respectively.

Aerodynamic properties of various crops

Grain Vcr kd k

Wheat 8.90 - 11.50 0.075 - 0.12 0.184 -0.265

Rey 8.36 – 9.89 0.10 - 0.14 0. 16 – 0.22

Oat 8.08 – 9.11 0.169 - 0.30 0.188 – 0.15

Corn 12.48 – 14.00 0.05 - 0.06 0.16 – 0.28

Chaff

Wheat 0.75 – 5.25

Oat 0.74 – 3.86

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Maize Sheller Design

A Schematic diagram of the maize Sheller: A = hopper; B = shelling cylinder; C =

rasp-bar; D = beater; E = concave screen extension; F = direction board; G = top
sieve; H = cob outlet; I = broken cob outlet; J = bottom sieve; K = chaff outlet; L =
kernel outlet; M = centrifugal fan; N = cam; O = stationary concave screen; and Q,
shelling chamber

Shelling cylinder: (a) front view; (b) side view; A, rasp-bar; B, rasp-bar mount; C,
cylinder.

The stationary concave screen: (a) front view; (b) section YY; A, concave screen
support; B, concave screen hole; C, concave screen bar; D, concave screen rib; E,
concave screen.
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Development of Groundnut Chaff Removing Machine

The velocity of the blade,

V=
√
3 P
ρA
The force exerted by the blower on a groundnut kernel of cross-sectional area A is given
by,

F=ρ AV 2
The forces acting on a kernel is given by the equation: -

R=√ F 2 + ( mg )
2

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