DESIGN AND FABRICATION OF A PALM KERNEL CRACKING MACHINE

BY

IBRAHIM IDOWU DA YID

200S/2216SEM

A PROJECT REPORT SUBMITTED IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE AWARD OF

BACHELOR OF ENGINEERING (B.Eng) DEGREE IN MECHANICAL ENGINEERING,

SCHOOL OF ENGINEERING AND ENGINEERING TECHNOLOGY FEDERAL UNIVERSITY OF TECHNOLOGY, MINNA NIGERIA

NOVEMBER 2010

CERTl}1~lCATION

This is to celtify that this proJect titled, Design and Fabrication of a Palm Kernel

Cracking Machine, was carric!d out by me, Ihrahim Idowu David with Matriculation .

Number, 200S/2216SEM under the supervision of Engr. OJ Onuoha and has been read and approved having met tile requiremtllt. for the aW2.:d of Bachelor of Engineering (B.Eng) Degree in Mechanical Engineering, of the Federru University of Technology Minna

Engr. 0.1 Onuoha '--- \~~~ ... 2-1r' Il ~ Project Supervisor Signature and Date

Professor R Khan

Head of department Signature and Date

External Examiner Signature and Date

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ACKNOWLEDGEMENT

I thank Almighty God for His endless guidance, protection and provisions during my

studies.

I am grateful to my beloved supervisor, Engr. O.J Onuoha, for his endless support,

encouragement and assistance during the course of this project.

My sincere appreciation goes to the Dean of Engineering, Professor Abolarin, Head of

Department, Professor RH. Khan, my Level Adviser, Dr. Ogwuoke Ikechukwu Celestine,

and all the lecturers and staffs of Mechanical Engineering Department for the effective

training given to me right from the start of my study.

My gratitude goes to my parents for their efforts and support since my birth to this moment,

especially my mother Mrs. Maria Ibrahim

I want to use this opportunity to acknowledge my brothers; Sunday, Segun, Bidemi, Ayo,

Jeffrey, Henry and Maxwell and sisters; Mrs. S.E 19u9o, Mrs. AH George, Kehinde for all

their contributions and prayers for me.

Lastly, I cannot but acknowledge my course mates, friends and those that have made great impacts in my life, Oluyinka, Arc. Gomna, Olive, Tunji, Bolaji, Charles. God bless you all.

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!~BSTRACT

Tll is work en tails the construction of a better model of palm kernel cracking machine. Studying

the existing crackers and their limitations as stated in the literature review it was observed that

the existing crackers have so many setbacks, some of the crackers cannot crack all the varieties

of palm kernel nut at the same time (the crackers are selective), this could be due to their, various

slwpes and sizes but this new machine can effectively crack varieties of kernel nut no matter the

sizes or shapes. The palm kernel cracking machine is power driven and it is constructed so as to

increase efficiency of cracking the nuts, reduce accidents during operation and minimize the

expellding o[ time during the process. From the design, it was concluded that this project would

considerably improve the productivity of palm kernel nut cracking not only in Nigeria but also in

otller countries where palm kernel nuts are being produced. It has an efficiency 0[75.5 %.

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TABLE OF CONTENTS

COVER PAGE

TITLE PAGE

DECLARATION

CERTIFICATION

DEDICATION

ACKNOWLEDGEMENT

ABSTRACT

TABLE OF CONTENTS

CHAPTER ONE

1.0 INTRODUCTION

1.1 BACKGROUND OF STUDY

1.2 ORIGIN OF THE OIL PALM

1.3 PROCESSING OF PALM KERNEL

1.4 USES OF PALM KERNELS

1.5 RESEARCH PROBLEM

1.6 JUSTIFICATION OF THE STUDY

1.7 OBJECTNES OF THE STUDY

CHAPTER TWO

2.0 LITERATURE REVIEW

2.1 TRADITIONAL METHODS

2.1 .1 Stone Arrangement Method

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VI

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2.1.2 Mortar and Pestle Method 9

2.2 MODERN METHODS 10

2.2.1 Manual Nut Cracking Machine 11

2.2.2 Hammer Mill Method 11

2.2.3 Air Operated Nut Cracker 12

2.2.4 Centrifugal Nut Cracker 12

CHAPTER THREE

3.0 MATERIALS AND METHOD 14

3.1 DESCRIPTION OF THE MACHINE 14

3.1.1 The Hopper 14

3.1.2 Cracking Chamber 14

3.1.3 Shaft 14

3.1.4 Bearing 15

3.1.5 Bearing Housing 15

3.1.6 Pulley 15

3.1.7 The Belt 15

3.1.8 The Cracking Mechanism 15

3.2 DESIGN CONSIDERATION 15

3.3 DESIGN ANALYSIS 16

3.3.1 Power Transmission and Shaft Design Analysis 18

3.3.2 Selection of Belt Tension 20

3.3.3 Bearing Selection Analysis 24

3.3.4 Shaft Design Analysis 25

3.3.5 Key Design Analysis 27

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.. 3

3.3.5.1 Design of a Rectangular Key

3.4 DESIGN CALCULATIONS

3.4.1 Detennination of the Velocity at which The Nut Enters The Cracking

Mechanism

3.4.2 Detennination of the Velocity of the Palm Kernel Nut

3.4.3 Detennination of the Cracking Force, F

3.4.4 Detennination of Speed of Shaft

3.4.5 Detennination of the Power Transmitted by the Shaft to the Cracking

Mechanism

3.4.6 Detennination of Power Loss due to Friction

3.4.7 Detennination of the Efficiency of Drive

3.4.8 Detennination of the Torque Transmitted by the Drive

3.4.9 Detennination of Centrifugal Velocity due to Belt

3.4.10 Detennination of Centrifugal Force due to Belt

3.4.11 Detennination of Centre Distance Between Pulleys

3.4.12 Detennination of the Effect of Belt Tensions

3.4.13 Detennination of Shaft Reactions

3.4.14 Detennination of Shaft Shearing Forces

3.4.15 Detennination of Shaft Bending Moment

3.4.16 Detennination of the Torsional Shear Stress of Key

3.4.17 Detennination of the Angle of Twist of Shaft

3.4.18 Detennination of the Number of Belts

3.4.19 Detennination of the Dynamic Load Rating for the Bearing

3.5 MATERIAL SELECTION

3.6 COST ANALYSIS

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CHAPTER FOUR

4.0 FABRICATION AND TESTING

4.1 FABRICATION

4.1.1 Making Out

4.1.3 Cutting

4.1.3 Welding

4.1.4 Grinding

4.1.5 Surface Finishing

4.1.6 Painting

4.2 MOISTURE CONTENT DETERMINATION

4.2 TESTING

4.3 DISCUSSION OF RESULTS

CHAPTER FIVE

5.0 CONCLUSION AND RECOMMENDATIONS

5.1 CONCLUSION

5.2 RECOMMENDATIONS

REFERENCES

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APPENDICES

Appendix I: Truncated Square base Pyramid of Hopper

Appendix IT: Table 1: Dimensions for the Standard V-Grooved Pulley according to IS: 2494

-1974

Table 2: Life of Bearings for Various Types of Machines

Table 3: Values of radial load factor(X) and axial load factor(Y) for the

dynamically loaded bearings

Table 4: Recommended values for Kb and Kt

Table 5: Keys dimensions based on the required diameter according to IS :

2292 & 2293 - 1974

Appendix ill: Constants used in calculation

LIST OF FIGURES

Figurel.l:

Figure 1.2:

Figurel.3:

Figure 1.4:

Figure 3.1:

Figure 3.2:

Figure 3.3:

Figure 3.4:

Figure 3.5:

Figure 3.6:

Cross-section of Oil Palm Kernel Friut

Type of Tenera Palm Nuts

Palm Oil Processing Flowchart

Palm Kernel Processing Flowchart

Schematic diagram of palm kernel cracking machine

Belt Cross - Section

Belt Diagram

Loading of Shaft

Loading of Shaft

Shear Force and Bending Moment Diagrams

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; ......

LIST OF TABLES

Table 3.1 Material, Quantity and Total Cost

Table 4.1 Results from the test carried out

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