Design and Fabrication of Reel Mower Cycle

I

E S

COLLEGE OF ENGINEERING

CHITTILAPPILLY, THRISSUR Dt., KERALA–680 551, www.iesce.info

MINI PROJECT REPORT ON

DESIGN & FABRICATION OF LAWN MOWER CYCLE Submitted By

ABDUL SAMAD P.R

(ISAMEME002)

ABHAY VISHNU V.S

(ISAMEME004)

JAFEER P.A

(ISAMEME022)

KIRAN JOSEPH

(ISAMEME026)

MOHAMED HUWAIS

(ISAMEME034)

DEPARTMENT OF MECHANICAL ENGINEERING APRIL 2015

Department of Mechanical Engineering CERTIFICATE Certified that this is a bonafide record of the Mini Project Work titled

“DESIGN AND FABRICATION OF LAWN MOWER CYCLE” Done by, ABDUL SAMAD.P.R

(ISAMEME002)

ABHAY VISHNU.V.S

(ISAMEME004)

JAFEER.P.A

(ISAMEME022)

KIRAN JOSEPH

(ISAMEME026)

MOHAMMED HUWAIS (ISAMEME034) of pre final year B Tech Mechanical Engineering in partial fulfillment of the requirement for the award of Bachelor of Technology Degree in Mechanical Engineering under the University of Calicut during the year 2012-2016.

__________ Mr. Nandan K Kuttan Asst. Professor (Guide)

____________ Dr. U. Mohammed Iqbal Head of the Department

Submitted for the Mini Project Viva-Voce Examination held on _ _ _ _ _ _ _

_________ Examiner I

__ ______ Examiner II

ACKNOWLEDGMENT We first of all we thank almighty for his blessing showered upon us in enabling us to complete this project on time. We thank Prof. Dr.V Jayaraman (Principal of, IES College of Engineering) for giving us a chance to fabricate this Mini project. We would like to thank our project guide Mr. Nandan K Kuttan, (Asst. Professor, IESCE) for giving us apt guidance. We would also like to extend our gratitude towards Dr. U. Mohammed Iqbal, (Head of the Department) for his invaluable support &suggestions throughout this project. We would also like to thank our project in charge Mr. Rinto K Anto, (Asst. Professor, IESCE) and Mr. Anil D Koola, (Asst. Professor, IESCE) for

their

continuing support in this endeavour. We would like to thank Mr. Febin V, (Lab Instructor, IESCE) for his valuable time and suggestions for fabrication of our project. Many people, especially our classmates and family members, who have made valuable comment suggestions on this proposal which gave us an inspiration to improve our project. We thank all the people for their help directly & indirectly to complete our project.

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TABLE OF CONTENTS

CHAPTER NO.

Chapter 1

Chapter 2

Chapter 3

TITLE

PAGE NO.

List of Figures

iv

List of Tables

v

Abstract

iv

INTRODUCTION

1-3

1.1

Relevance

2

1.2

History

2

1.3

Project Plan

3

LITERATURE REVIEW

4-24

2.1

The basics in grass cutting

4

2.2

Types of lawn mowers

6

2.3

Reel Mower Parts

14

2.4

Factors effecting clip

15

2.5

Set-up and Adjustments

19

2.6

Sharpening

23

COSTRUCTION DETAILS

25-30

3.1

Selecting Required Cycle Frame

25

3.2

Mower Frame

26

3.3

Reel

26

3.4

Bed Knife

27

3.5

Main wheel with internal gears

28

3.6

Trolley Wheels

29

3.7

Balancing Wheels

29

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Chapter 4

WORKING PRINCILE

31

Chapter 5

DESIGN CALCULATIONS

32-34

5.1

Spur & pinion Gear parameters

32

5.2

Deign Specification

33

5.3

The Cutting blades Design

33

5.4

Performance test and evaluation

34

Chapter 6

Chapter 7

RESULTS & DISCUSSIONS

35-38

6.1

Discussion

35

6.2

Applications

35

6.3

Advantages

35

6.4

Design

36

6.5

Estimate

37

CONCLUSION & FUTURE SCOPE

39

7.1 Conclusion

39

7.2 Future Enhancements

39

REFERENCE

40

iii

LIST OF FIGURES Figure No.

Name

PageNo.

Figure 2.1

Mulching

4

Figure 2.2

Spreading

5

Figure 2.3

Bagging

5

Figure 2.4

Push lawn reel mower

6

Figure 2.5

A rotary mower (viewed from underneath)

9

Figure 2.6

A Cordless electric mower

10

Figure 2.7

Hover mower

11

Figure 2.8

Robotic mower

12

Figure 2.9

A tractor-pulled mower

12

Figure 2.10

Zero turn mower

13

Figure 2.11

Bed knife

14

Figure 2.12

Clip and the shear point

15

Figure 2.13

Illustration of actual grass cutting process

16

Figure 2.14

Grass cutting process showing HOC

16

Figure 2.15

Clip distance and shear points

17

Figure 2.16

Side view showing bedknife during grass cutting

18

Figure 2.17

Front view of Reel mower showing Helix angle

18

Figure 2.18

Cutting path

19

Figure 2.19

Single point reel to bedknife adjust

21

Figure 2.20

Cutting unit dulling curve

22

Figure 2.21

Sharpening of blades

23

Figure 2.22

Lapped Surfaces

24

Figure 3.1

Different Body Position

25

Figure 3.2

Mower Frame

26

Figure 3.3

Reel: Helix shaped Spiral Blades

27

Figure 3.4

Bed Knife

28

Figure 3.5

Pinion Gear & Main wheel

28

Figure 3.6

Trolley wheels for supporting mower

29

Figure 3.7

Balancing wheel and frame

29

Figure 3.8

Lawn mower cycle after construction

30

Figure 6.1

View of mower Assembly

36

iv

LIST OF TABLES Table No.

Name

Page No.

Table 6.1

Cost estimation

37

Table 6.2

Materials used

38

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Lawn Mower Cycle

Mini Project

ABSTRACT The design objective is to come up with an apparatus for cutting grass that is portable, durable, easy to operate and maintain. It also aims to design a pedal- powered Mower cycle. The pushing force required for moving the reel mower is obtained from the motion of a bicycle. The Mower cycle consists of three main wheels with two of the wheels at the front. Between the two front wheels a cutting mechanism is made with internal spur gear system which transfers the torque to the mower spiral mechanism. The cutting mechanism is made of a flat blade rigidly fixed to the frame behind the spiral arrangement which is configured to contact at least one reel bar of the spiral blades during the rotation of the spiral mechanism.

Dept. of Mechanical Engineering

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CHAPTER 1 INTRODUCTION Lawn mower is an essential tool for the maintenance of yards. They vary in size, mode of operation and power. The power source riding mowers for example are usually powered by a gasoline engine and are ridden and steered by the operator but they are costly. So our design objective is to come up with a Lawn mower cycle that is durable, cost efficient & easy to operate. The Lawn mower cycle is peddle powered. The power required to push the mover is obtained from a chain-driven cycle. This project attempts to combine a cycle and a mower. There are primarily two types of mowers namely (i) the reel mowers, and (ii) the rotary mowers. The reel (cylindrical) mowers seem to be better. Made of blades on a revolving cylinder, they achieve clean cut by scissors action. As the mower moves forward, the rotating blades come in contact with a stationary bar called the bed knife and placed parallel to the ground. Grass is held by the shearing action of the reel blades against the bed knife. The mower is adjusted to various cutting heights. Rotary mowers are often powered either by an internal combustion engine or an electric motor and are generally moved manually, with the engine only spinning the cutting blades.

Dept. of Mechanical Engineering

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1.1 RELEVANCE The main aim of our project is to come up with a cost efficient lawn mower. A lawn mower is a machine used for cutting grass or lawns. A lawn is any area of grass; mostly tough grass which is neatly cut like in a private garden or a public park. Walk behind mowers are designed to be pushed by the operator and typically run on gasoline or electricity. Modern gas powered and electric powered lawn mowers cut grass with a single blade revolving at a high speed parallel to the ground. Generally, in areas like ours, the conventional methods of grass cutting involved the use of cutlasses which never met the maximum satisfaction. More so, it is strenuous, time and labour intensive. Therefore, there is the need to develop a low cost mower which can take care of this operation easily. The objective of the study is to design and develop a locally fabricated peddle powered spiral blade lawn mower affordable by common man

1.2 HISTORY The first lawn mower was invented in 1830 by Edwin Beard Budding .He was said to obtain the idea after watching a machine in a local cloth mill which used a cutting cylinder mounted on a bench to trim clothes for a smooth finish after weaving. Budding realized that a similar concept could be used to cut grass if the mechanism is mounted in a wheel frame to enable the blades rotate close to the lawns surface. These early machines were made of cast iron and featured a large rear roller with a cutting cylinder (reel) in the front. Cast iron gear wheel transmitted power from the rear roller to the cutting cylinder. In 1832, Ransoms of Ipswich (under license) began the making of Budding‘s mower. This company is today the world‘s largest manufacturer of lawn care equipment. By mid 1850, Thomas Green developed a mower which used chains to transmit power from the rear roller to the cutting cylinder. It was called ‗Silens Messor‘ meaning silent cutter. The machines were found comparatively lighter and quieter than the gear driven machines that preceded them. By late 1890, motorized mowers appeared as light weight petrol engines and small steam power units became available.

Dept. of Mechanical Engineering

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Lawn Mower Cycle

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In US, Colonel Edwin George produced the first gasoline powered mower in 1919. Electric powered mowers and rotary cutting machines emerged in the 1920‘s and 1930‘s. By 1960 the introduction of plastic components greatly reduced cost. Today, new technology has brought new improved versions. Low emission gasoline engines with catalytic converters are introduced to help reduce air pollution. Improved muffling devices are also incorporated to reduce noise. Today, the recent innovation is the rotary hover mower.

1.3 PROJECT PLAN The design objective is to come up with a mower cycle that is durable, cost efficient & easy to operate. The mini project mainly consists of 7 Chapters. The first chapter is introduction part where we explain the basic concepts. The second chapter is literature review. This chapter explains the components and features of lawn mower cycle. The third chapter is design part where we explain how we made the required machine. Then the later chapters deals with results and discussions.

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CHAPTER 2 LITERATURE REVIEW

2.1 THE BASICS IN GRASS CUTTING Grass as most other plants grow during a certain period of the year. This can off course differ some depending on where in the world you are. For India, the grass starts to grow in April. From then to June the grass has its high season, which means it‘s grows fast and strong. During this period you can cut the grass 1-2 times a week. What you should think of is to take it easy in the beginning of the growth period as not to stress the grass. The grass is then entering a period of low growing rate, mostly due to the sun, drying the soil. You should take care not to cut the grass to short if the grass looks dry (turning somewhat yellow). A good rule is to cut about one third of the grass length at a time. The grass can be very sensitive and can be damaged if you cut too much at one time. Then we come to the length. Here it really depends on what kind o a lawn you‘re aiming for. If you want a lawn that you can walk on you should leave at least 4cm of the grass. There are different approaches to cutting the grass all with advantages and disadvantages. 2.1.1 Mulching When mulching you cut the grass in to small pieces that you leave on the ground to work as a natural fertilizer. The negative side is that you will have to cut more often to let the mower cut the grass correctly.

Figure 2.1 Mulching

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2.1.2 Spreading Spreading means that the mower spread the cut grass directly on to the lawn. Depending on the amount of cut grass you might have to rake it together. The downside is the extra work but on the other hand you will have grass to make fresh soil to use in your garden. If you cut the grass when it‘s long another downside can be that the cut grass can suffocate the living grass.

Figure 2.2 Spreading

2.1.3 Bagging Bagging involves a container that directly collects the grass for you to later empty at a pleasant spot. The downside is that it claims more energy from the mower or you to carry it around until you have emptied it.

Figure 2.3 Bagging

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2.2 TYPES OF LAWN MOWERS

2.2.1 Reel (cylinder )mowers The reel (cylindrical) mower is made of blades on a revolving cylinder, they achieve clean cut by scissors action. As the mower moves forward, the rotating blades come in contact with a stationary bar called the bed knife and placed parallel to the ground. Grass is held by the shearing action of the reel blades against the bed knife. The mower is adjusted to various cutting heights. Of all the mowers, a properly adjusted reel mower makes the cleanest cut of the grass, and this allows the grass to heal more quickly. The cut of a well-adjusted cylinder mower is straight and definite, as if cut with a pair of scissors. This clean cut promotes healthier, thicker and more resilient lawn growth that is more resistant to disease, weeds and parasites. Lawn cut with a cylinder mower is less likely to result in yellow, white or brown discolouration as a result of leaf shredding. While the cutting action is often likened to that of scissors, it is not necessary for the blades of the spinning cylinder to contact the horizontal cutting bar. If the gap between the blades is less than the thickness of the grass, a clean cut can still be made. If more however, the grass will slip through.

Figure 2.4 Push lawn reel mower

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There are many variants of the cylinder (reel) mower. Push mowers (illustrated) have no engine and are usually used on smaller lawn areas where access is a problem, where noise pollution is undesirable and where air pollution is unwanted. As the mower is pushed along, the wheels drive gears which rapidly spin the reel. Typical cutting widths are 10 to 16 inches (410 mm). Advances in materials and engineering have resulted in these mowers being very light and easy to operate and manoeuvre compared with their predecessors while still giving all the cutting advantages of large professional cylinder mowers. Their distinct environmental benefits, both in noise and air pollution, are also strong selling points, something not lost on many international zoos, animal sanctuaries and exclusive hotel groups. The basic push mower mechanism is also used in gangs towed behind a tractor. The individual mowers are arranged in a "v" behind the tractor with each mower's track slightly overlapping that of the mower in front of it. Gang mowers are used over large areas of turf such as sports fields or parks. A gasoline engine or electric motor can be added to a cylinder mower to power the cylinder, the wheels, the roller, or any combination of these. A typical arrangement on electric powered machines for residential lawns is for the motor to power the cylinder while the operator pushes the mower along. The electric models can be corded or cordless. On petrol machines the engine drives both the cylinder and the rear roller. Some variants have only three blades in a reel spinning at great speed, and these models are able to cut grass which has grown too long for ordinary push mowers. One type of reel mower, now largely obsolete, was a powered version of the traditional side-wheel push mower, which was used on residential lawns. An internal combustion engine sat atop the reel housing and drove the wheels, usually through a belt. The wheels in turn drove the reel, as in the push mower. Greens mowers are used for the precision cutting of golf greens and have a cylinder made up of at least eight, but normally ten, blades. The machine has a roller before and after the cutting cylinder which smooths the freshly cut lawn and minimizes wheel marks. Due to the weight, the engine also propels the mower. Much smaller and lighter variants of the roller mower are sometimes used for small patches of ornamental lawns around flower beds, and these have no engine. Riding reel mowers are also produced.

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Typically, the cutting reels are ahead of the vehicle's main wheels, so that the grass can be cut before the wheels push the grass over onto the ground. The reels are often hydraulically powered. The main parts of a cylinder or reel mower are: 1. Blade reel/cylinder — consist of numerous (3 to 7) spiral blades that are attached to a rotating shaft. The blades rotate, creating a scissor-like cutting motion. 2. Bed knife — is the stationary cutting mechanism of a cylinder/reel mower. This is a fixed horizontal blade that is mounted to the frame of the mower. 3. Body frame — the main structural frame of the mower onto which the other parts of the mower are mounted. 4. Wheels — these help propel the mower in action. Generally, reel mowers have two wheels. 5. Push handle — the "power source" of a manually operated reel mower. This is a sturdy T-shape handle that is connected to the frame, wheels and blade chamber. 6. Motor — the power source of a reel mower that is powered by gasoline or electric.

2.2.2 Rotary mowers A rotary mower rotates about a vertical axis with the blade spinning at high speed relying on impact to cut the grass. This tends to result in a rougher cut and bruises and shreds the grass leaf resulting in discolouration of the leaf ends as the shredded portion dies. This is particularly prevalent if the blades become clogged or blunt. Most rotary mowers need to be set a little higher than cylinder equivalents to avoid scalping and gouging of slightly uneven lawns, although some modern rotaries are fitted with a rear roller to provide a more formal striped cut. These machines will also tend to cut lower (13 mm) than a standard four-wheeled rotary. The main parts of a rotary mower are: 1. Cutter deck housing — this houses the blade and the drive system of the mower. It is shaped to effectively eject the grass clippings from the mower. 2. Blade mounting and drive system — the blade of a rotary mower is usually mounted directly to the crankshaft of its engine, but it can be propelled by a hydraulic motor.

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3. Mower blade — a rotary mower generally has one blade that rotates horizontally. The blade features edges that slightly curved up to generate a continuous air flow as the blade rotates, thus creating a sucking and tearing action. 4. Engine — may be powered by gasoline or electricity. 5. Wheels — rotary mowers generally feature a set of four wheels; two front wheels and two rear wheels.

Figure 2.5 A rotary mower (viewed from underneath), with a mulching blade that rotates around the center.

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

Dept. of Mechanical Engineering

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2.2.4 Electric mower Electric mowers are further subdivided into corded and cordless electric models. Both are relatively quiet, typically producing less than 75 decibels, while a gasoline lawn mower can be as loud as 95 decibels or more. Corded electric mowers are limited in range by their trailing power cord, which may limit their use with lawns extending outward more than 100–150 feet (30–45 m) from the nearest available power outlet. There is the additional hazard with these machines of accidentally mowing over the power cable, which stops the mower and may put users at risk of receiving a dangerous electric shock. Installing are sidual-current device (GFCI) on the outlet may reduce the shock risk. Cordless electric mowers are powered by a variable number (typically 1-4) of 12-volt rechargeable batteries. Cordless mowers have the maneuverability of a gasoline powered mower and the environmental friendliness of a corded electric mower, but are more expensive and come in fewer models.

Figure 2.6 A Cordless electric mower

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2.2.5 Hover mower Hover mowers are powered rotary push lawn mowers that use an impeller above the spinning blades to drive air downward, thereby creating an air cushion that lifts the mower above the ground. The operator can then easily move the mower as it floats over the grass. Hover mowers are necessarily light in order to achieve the air cushion and typically have plastic bodies with an electric motor. The most significant disadvantage, however, is the cumbersome usability in rough terrain or on the edges of lawns, as the lifting air-cushion is destroyed by wide gaps between the chassis and the ground. Hover mowers are built to operate on steep slopes, waterfronts, and high-weeded areas, so they are often used by golf course greens keepers and commercial landscapers

Figure 2.7 Hover mower (underside view).

2.2.6 Robotic mower A robotic mower is contained by a border wire around the lawn that defines the area to be mowed. The robot uses this wire to locate the boundary of the area to be trimmed and in some cases to locate a recharging dock. Robotic mowers are capable of maintaining up to 5 acres (20,000 m2) of grass. Robotic lawn mowers are increasingly sophisticated, are usually self-docking and contain rain sensors, nearly eliminating human interaction for mowing grass. Multiple robotic mowers can be used to mow an even larger area.

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Figure 2.8 Robotic mower

2.2.7 Tractor pulled mower These are usually in the form of an attachment to a tractor. The attachments can simply function by the movement of the tractor similar to manual push cylinder mowers, but also sometimes may have powered moving blades. They are commonly mounted on either the side or the back of the tractor.

Figure 2.9 A tractor-pulled mower

Dept. of Mechanical Engineering

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2.2.8 Zero-turn riding lawn mower A zero-turn riding lawn mower (colloquially, a z-turn) is a standard riding lawn mower with a turning radius that is effectively zero. Different brands and models achieve this in different ways, but hydraulic speed control of each drive wheel is the most common method. Both commercial duty and homeowner models exist, with varying engine power options, size of cutting decks, fuel type (gasoline or diesel), and prices. A z-turn mower typically drives faster and costs more than a similarly sized conventional riding mower that has steerable front wheels. Most current models have four wheels: two small swiveling front tires and two large drive tires in the back. Bush Hog mowers sometimes come with a small, pivoting fifth wheel mounted in the center behind the driver. Instead of controlling the swiveling tires to steer the machine, the large drive tires rotate independently of each other based on the driver's input. They may rotate in opposite directions. The mower can pivot around a point midway between the drive wheels (the classic z-turn), or it can pivot around either one of the drive wheels if one is stationary, or it can turn in a circle of any radius. Reversal of the direction of travel can be accomplished by causing both wheels to rotate in reverse.

Figure 2.10 Zero turn mower

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2.3 REEL MOWER PARTS There are three main structural members in a reel cutting unit: 1. The REEL consists of varying numbers of helix shaped blades attached to support spiders which are mounted on a rotating shaft. 2. The BEDKNIFE is attached to the bedbar and the assembly is mounted to the main frame in a manner that allows for paralleling and adjustment to the reel. 3. The FRAME supports the rollers, the bedbar assembly and reel with its drive mechanism, which can be hydraulic, belt driven or ground driven. A reel mower cuts grass with a scissors-like shearing action as the moving helix shaped blades pass over the stationary bedknife.

Figure 2.11 Bed knife

The cutting action requires that the bed knife and reel blades be sharp, matched, and in close relationship with each other. When properly maintained and operated, reel mowers provide superior quality of cut. It cannot be overstated that reel mowers are precision tools. It is essential that they be adjusted and operated with this in mind.

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

Figure 2.12 Clip and the shear point

2.4 FACTORS AFFECTING CLIP 1. The diameter of the reel 2. The number of reel blades 3. The speed of the reel 4. The ground speed

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

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Figure 2.13 Illustration of actual grass cutting process

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

Figure 2.14 Grass cutting process showing HOC

Grass extending beyond the forward half clip, yet tall enough to be within the blade path is less likely to be cut. Reel blades may contact the grass in this area several times prior to the actual gathering of the grass. This is the so called ―fanning‖ process.

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This process is more a mechanical striking of the grass that it is of the commonly thought effect of a blowing action.

Figure 2.15 Clip distance and shear points

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The importance of the bedknife front angle is visible from the side view. Note that (from Figure 2.16) the proper angle allows the grass behind the bedknife front edge to be more effectively cut.

Figure 2.16 Side view showing the bedknife during grass cutting

Figure 2.17 Front view of Reel mower showing Helix angle

Cutting path: Another term known as ―the cutting path‖ is the result of the helix angle and the forward motion of the cutting unit. The shear point moves down the bedknife as the bedknife moves forward. The grass is physically cut at an angle to the bedknife.

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Figure 2.18 Cutting path

Other factors which affect reel mowing are the grass density and the grass acclimation or grain. Grass tends to thicken at the normal maintained height of cut. The denser the grass, the easier it is for the bedknife and reel to gather it. Grass density and grain can often override other factors we have discussed regarding the cutting action. The basic requirements for good performance of reel mowers are: 1. The cutting edges on the reel blades and bedknife must be straight and sharp. 2. The bedknife must be exactly parallel with the reel. 3. The bedknife should be positioned against the reel with light contact.

2.5 SET-UP AND ADJUSTMENTS Reel mower performance depends on proper set–up and adjustment procedures. An error of .010 inch or .25 mm, in height end–to–end, or from one cutting unit to another, is visible as a mismatch on many golf course greens. Although there are design variations in cutting units, most require the same basic procedures. A surface plate, accurate height of cut tools and proper instruction are essential for setting up a cutting unit.

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There are many factors that can affect quality of cut, including condition of the mowing equipment and agronomic factors. Turf conditions such as excessive thatch, ―sponginess‖ or attempting to cut off too much grass height may not always be overcome by adjusting the machine. It is important to remember that the lower the height of cut, the more critical these factors are. Remember that the ―effective‖ or actual height of cut depends on cutting unit weight, cutting unit accessories and turf conditions. Effective height of cut will be different than the bench set height of cut. Effective height of cut is the actual height the grass has been cut. Making an accurate height measurement on the turf is difficult due to many variables. A true base is simply not present. If the surface is uneven, spongy or varies in density, color variations in the turf may appear in the form of a streak. This is due to the effective height of cut being too low for the existing turf conditions. To correct problems, start or change a cultural practice, change cutting unit configuration or raise the bench set height of cut. The lower your height of cut, the more predictable and smooth the turf surface must be. To accurately maintain height of cut and performance, routinely check the following components: 1. Reel Bearings 2. Bedknife to Reel Adjustment 3. Attitude Adjustment 4. Roller Parallelism 5. Height of Cut

2.5.1 Reel to Bedknife adjustment Single point adjust cutting units also have an adjustment mechanism on one end of the bedknife for adjusting the bedknife parallel to the reel. This bedknife leveling mechanism could may be an eccentric pivot bolt on one end of the bedbar, or a capscrew / jam nut assembly.

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Figure 2.19 Single point reel to bedknife adjust

Adjust the bedknife against the reel to evenly pinch one paper thickness across the entire width of the bedknife, then cut paper strips to check blade sharpness. Put the cutting unit on the turf and check for light bedknife to reel contact and free reel rotation. Do a final adjustment of bedknife to reel contact if necessary. Properly adjusting the bedknife to the reel is one of the most effective preventive maintenance practices for reel mowers. The amount of contact and how frequently it is checked are major factors in performance. A light contact adjustment, if maintained, will help keep cutting edges sharp on the reel and bedknife. This requires that the adjustment be checked frequently at a predetermined time interval. Dulled cutting edges cannot be corrected immediately by adjustment or over– tightening. Do not wait until the quality of cut has deteriorated to check the bedknife to reel adjustment. If the cutting edges on the reel blades and bedknife are not straight and sharp the mowing results may not be acceptable. This is true even if all other set–up procedures are correct.

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Figure 2.20 Cutting unit dulling curve

The cutting unit attitude is the angle between the bottom of the bedknife and the ground plane under the cutting unit. As the bedknife attitude is changed, it is important to note that the reel to bedknife shear point changes relative to the center line of the reel. This can change the after cut appearance of the grass. The result may be better or worse depending on several factors The result may be better or worse depending on several factors. Bedknife attitude is adjusted by changing the height of the front, rear, or both rollers. A height of cut change is NOT necessarily part of a change to the bedknife attitude. A large angle is also referred to as an aggressive bedknife attitude. A small angle (flat attitude) can have most or all of the bedknife riding ON the turf. This can influence after cut appearance.

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2.6 SHARPENING Cutting units should be kept as sharp as possible to: 1. Promote growth of healthy grass. 2. Optimize cutting unit performance. 3. Extend the life of the mower. 4. Maximize operator mowing time. 5. Allow the tractor to run most efficiently. 6. Provide excellent finished appearance of the turf.

Reel blades, and the edge of the bedknife should be checked for damage visually & by carefully feeling the edges. Of course, this should only be done when it is certain that the reel cannot be started, and never slide your fingers down the edges lengthwise. Rounded edges on the reel blades and bedknife will cause the grass blades to be pinched and torn, rather than sheared off cleanly. When light contact is not maintained, dull edges will soon result. Sharpening will also be required if the reel is ―cone shaped‖ (tapered). All reels eventually become tapered with use. If the reel is not adjusted or ground to a cylinder shape again, a mismatch in the height cut between adjacent reels can result.

Figure 2.21 Sharpening of blades

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There are several methods that may be used to sharpen a cutting unit. The one that you choose will depend upon the condition of the cutting unit. It should also make the most sense for the anticipated use. For example, if you are about to mow greens that have been core aerated or topdressed, you may not want to grind the reels and install new bedknives. As the reel blades run against the bedknife a slight burr will appear at the front cutting edge surface the full length of the bedknife. Occasionally run a file or facing grinder across the front edge to remove this burr to extend the cutting performance of the machines, Lapping must be done after single blade grinding. This is done to establish a ―land area‖ and to insure a perfect match between the bedknife and the reel edge. Lapping is not intended to be a reconditioning process to correct severely nicked or rounded blades, rifling or taper. If, after 5 minutes of lapping, the edge is not restored, it is time to grind the reel.

Figure 2.22 Lapped Surfaces

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CHAPTER – 3 CONSTRUCTION DETAILS

3.1 SELECTING REQUIRED CYCLE FRAME Different products come in different styles. One product category where this is a fact is the bicycle category. Getting the right impression of the product as well as considering the way it is being used is important, both when it comes to emotional aspects but also ergonomics and user interaction. The speed of a lawnmower is not that high so the aggressive style presented below is a bit too much even if it is effective considering the amount of energy that you can provide from that position. If we see to the demanded speed and wanted input power the formal style is the one best suited for our project. An honest expression with good ergonomically & mechanical possibilities is the position we chose to work with. Hence after necessary research a bicycle frame which gives a formal body position was chosen.

Figure 3.1 Different Body Position

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3.2 MOWER FRAME

Figure 3.2 Mower Frame

The frame is the main structural unit of the mower onto which the other parts of the mower are mounted. The frame is that provides a base unit that all of the components /subsystems are mounted on. The frame supports the Trolley wheels, the bedbar assembly and the reel with its drive mechanism. The Mower Frame is made of cast iron.

3.3 REEL The Reel consists of varying numbers of helix shaped blades attached to support spiders which are mounted on a rotating shaft. The reel is made up of six smaller blades of sizes 310mm x 25mm x 2mm and is made of steel materials. The blades are mounted on the three spiders rigidly fixed to the shaft and are oriented at a helical angle of 12 degree to the horizontal on the circular spiders for efficient grass cutting.

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Figure 3.3 Reel: Helix shaped Spiral Blades

3.4 BED KNIFE The Bedknife is attached to the bedbar and the assembly is mounted to the main frame in a manner that allows for paralleling and adjustment to the reel. The bedknife takes up almost the entire distance between the wheels on each end, and determines the cutting width of the mower. As the movable blades on the reel pass by the bed knife, the grass trapped between the blades and the bed knife is sheared off. The slight space between the bed knife and the reel is adjusted by a precision screw mechanism The bedknife is also made of steel material of size 300mm x 55mm x 2.6mm. Its edge is grinded with a front relief angle of 30 degree to make grass cutting easy in a scissor action with the reel. The bed-knife is fixed to the machine frame behind the reel.

Dept. of Mechanical Engineering

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Figure 3.4 Bed Knife

3.5 MAIN WHEEL WITH INTERNAL GEARS

The pinion gear transfers the power from the rotation of the main wheel to the axle and spinning blades. Driving gear has 72 teeth & the pinion gear has 13 teeth. These gears are mounted on the mower frame.

Figure 3.5 Pinion Gear & Main wheel

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3.6 TROLLEY WHEELS Trolley wheel acts as a support for the mower and it also helps in the movement of entire mower assembly. Trolley wheels are attached to mower frame by means of M.S flat bars.

Figure 3.6 Trolley wheels for supporting mower

3.7 BALANCING WHEELS A frame for balancing wheel is made of M.S flat bars. Rubber trolley wheel of 5.5 inch diameter is used as balancing wheels. These wheels support mower cycle and also give an easiness to steer the mower cycle.

Figure 3.7 Balancing wheel and frame

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Figure 3.8 Lawn mower cycle after construction

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CHAPTER – 4 WORKING PRINCILE OF LAWN MOWER CYCLE The cutting mechanism is made of a flat blade rigidly fixed to the frame behind the spiral arrangement which is configured to contact at least one reel bar of the spiral blades during the rotation of the spiral mechanism. To understand reel cutting theory, we must understand the concept of clip and the shear point. A shear point is any single point of contact made between the reel blade and bedknife. Clip is the forward distance traveled between successive blade contacts at one shear point. The bedknife pushes grass toward the shear point while the reel blade gathers it in front. Each blade path has one-half clip in which to cut all the grass. The pushing force required to move the reel mower is given by the motion of bicycle.

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CHAPTER – 5 DESIGN CALCULATIONS

5.1 SPUR & PINION GEAR PARAMETERS The gear train of a reel mower consists of a driving internal spur gears fixed to each of the front wheels internally which transmits the torque from the wheels to the reel, through the pinions on the shaft.

Using the Gear ratio/ speed ratio relation ω1 ω2

=

T2

---------(5.1)

T1

Where, 𝜔1 = Angular velocity of driving gear (rads/s) 𝜔2 = Angular velocity of driven gear (rads/s) 𝑇1 = Number of teeth on driving gear 𝑇2 = Number of teeth on driven gear

Gear ratio =

T2 T1

=

13 72

=

0.18055

---------(5.2)

Gear ratio is 1: 5.54

Module for internal spur gear (driving gear) Module,

M=

𝑑1 𝑇1

=

180 72

= 2.5

---------(5.3)

Where, 𝑑1 = pitch circle diameter of driving gear (m) 𝑇1 = Number of teeth on driving gear

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Module for pinion gear (driven gear) Module,

M=

𝑑2 𝑇2

=

32.5 13

= 2.5

---------(5.4)

Where, 𝑑2 = pitch circle diameter of driven gear (m) 𝑇2 = Number of teeth on driven gear

5.2 DEIGN SPECIFICATION

The following were chosen as the design standards. Average forward speed of the machine = 0.8m/s Speed of rotation of the blade = 1500rpm Number of helical blades = 6 Length of bed-knife = 300mm. The above specifications were chosen for operational convenience (From Kepner, Principles of farm machinery 1980).

5.3 THE CUTTING BLADES DESIGN The cutting blades are chosen as they appear in the spiral blade lawn mower. The blades are in two sets, the bed-knife and the reel. The reel is made up of six smaller blades of sizes 310mm x 25mm x 2mm and is made of steel materials. The blades are mounted on the three spiders rigidly fixed to the shaft and are oriented at a helical angle i. The helix inclination angle i for a cylinder having n partial helices is given by,

Cot i = i = 𝐶𝑜𝑡 −1

𝑛𝐿

---------(5.5)

2𝜋r 𝑛𝐿 2𝜋r

= Cot −1 (

6 × 0.310 2π × 0.052

) = 11.08 degree

Where,

L=Length of the cylinder (m) r = radius of the cylinder (m) i = helix inclination angle (degree)

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5.4 PERFORMANCE TEST AND EVALUATION The performance of the machine was evaluated through a field test. A land predominantly covered with grass was mapped out into a plot of area 4mx2m.

Theoretical field capacity, FCt = Vt × Wt

---------(5.6)

= 0.8 × 0.310 = 0 .248m2 /s

Where, Vt = Forward speed (m/s) 𝑊𝑡 = Theoretical width (m)

Effective Field capacity, FCe = A/t

---------(5.7)

= (4× 2)/90 =

0.08889 m2 /s

Where, A = Actual area covered by mower cycle (m2 ) t = Total time taken to cut the grass for a given area ( sec)

Field efficiency, FC

 FCe × 100 %---------(5.8) t

0.08889



0.2480

× 100

Where, FCe = Effective Field capacity (m2 /s) FCt = Theoretical field capacity (m2 /s)   

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CHAPTER 6 RESULTS AND DISCUSSIONS

A lawn mower cycle was designed, fabricated and tested. The mower is powered by the pushing force of cycle. This grass cutting machine can be used by both rural as well as urban dwellers. It is also affordable since the cost of production is low

6.1 DISCUSSION The performance test of lawn mower cycle is carried out on a lawn. The Effective field capacity (FCe), Theoretical field capacity ( FCt ) and field efficiency(%) are found out .The effective field capacity is obtained as 0.08889 m2 /s and Field efficiency (%) as 35.84 %, with an operating time of 90 seconds (1.5 minutes) . The theoretical field capacity (FCt) of the machine was calculated to be 0.248 m2 /s with a forward speed of 0.8m/s and the theoretical width of 0.31m. The machine was seen to be more effective when working in a dry soil condition, because there is proper gripping of the tyres in a dry condition of the soil.

6.2 APPLICATION A lawn mower cycle is a machine used for cutting grass in lawns at the required height.

6.3 ADVANTAGES 1. Low Cost 2. They are less dangerous than rotary mowers. 3. Require little maintenance. 4. Are environmentally friendly. 5. Produce little noise. 6. Are easy to transport and store. 7. Don't stir up dust or emit harmful fumes. 8. Don't fill debris around the yard.

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6.4 DESIGN

Figure 6.1 View of mower Assembly

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6.5 ESTIMATE A manufacturing process concerned with conversion of raw materials into finished products with the help of labor and other services. In order to compute the cost of each of these factors the cost of manufacturing is subdivided into what are known as elements of cost. Elements of cost are the primary classifications of cost according to the factors upon which expenditure is incurred the elements of cost that constitute total cost of a product are: i. Material cost ii. Labor cost iii. Other expenses

TABLE 6.1 COST ESTIMATION

Sl.No.

Part Name

Size/No.

Cost

1

Pinion Gear

2 nos

160

2

Main Gear Wheel

2 nos

750

3

Reel blades

1 nos

1050

4

Mower Frame

1 nos

600

5

M.S Rods

2 m length

250

6

Bicycle Parts

1 nos

500

7

M.S strips

1m length

105

8

Trolley Wheels

2 nos

70

9

Balancing Wheels

5 inch dia/ 2 nos

150

10

Nuts & Bolts

90

11

Workman ship

a)MI2/2 nos b) M14/6 nos c) M18/2nos -----

Total

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TABLE 6.2 MATERIALS USED

No

Parts Name

Materials Used

Quantity

1

Pinion Gear

H.S.S

2

2

Main Mower Wheel

Cast iron

2

3

Reel blades

Steel

6

4

Mower Frame

Cast iron

1

5

Bicycle Frame

G.I. Steel

1

6

Trolley Wheels

Rubber

2

7

Balancing Wheels

Rubber

2

8

Nuts & Bolts

Mild steel

10

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CHAPTER 7 CONCLUSION AND FUTURE SCOPE 7.1 CONCLUSION The aim of our project is to design, fabricate a lawn mower cycle. This does not have engine and is powered by a cycle. The machine is simply powered by the pushing force of a cycle. It is also affordable since the cost of production is low. This project helped us to improve our practical knowledge and also to express a new idea on the work shop. However by completing this project, we feel that our aim and objectives of the project is fulfilled.

7.2 FUTURE ENHANCEMENTS 7.2.1 Energy storage The Lawn mower cycle can be modified to an electric hybrid lawn mower, getting its power from a battery and by human power given by pedaling. It would increase the overall capacity of the machine as more energy would be available.

7.2.2 Back Wheel steering The back wheel steering can be added to this machine so that the lawn mower cycle can be easily turned in different angles. This ensures a good control and making it possible to turn around hard corners and small obstacles.

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REFERENCES 1. Atkins, T. (2005). Optimum blade configuration for the cutting of soft solids. 2. Basil Okafor, International Journal of Engineering and Technology Volume 3 No. 10, October, 2013 Simple Design of Self-Powered Lawn Mower 3. Fundamentals of Reel Mowers by TORO Commercial products 4. Jeremy, J. (2005). Solar charged lawnmower (28th Jan. 2010). 5. Khurmi, R.S. and Gopta, J.K. (1997). Machine Design, 11th Edition. Eurasia Publishing House Ltd. New Delhi 6. Kepner, R.A., Bainer, R., & Boroger, E. L . (1980). Principles of farm machinery 7. Kinnander, Ola (October 25, 2012). "Rise of the Lawn-Cutting Machines". Bloomberg Businessweek. 8. Nathan Fletcher, (2007) University Of Louisville , Design project 9. S.O. Nkakini, European International Journal of Science and Technology Vol. 3 No. 4 May, 2014 Design, fabrication and evaluation of a spiral blade lawn mower 10. Yong and Chow, S.H. (1991). Design and Construction of an Improved Domestic

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