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International Journal of Application or Innovation in Engineering & Management (IJAIEM)

Web Site: www.ijaiem.org Email: editor@ijaiem.org, editorijaiem@gmail.com


ISSN 2319 - 4847
Special Issue for National Conference On Recent Advances in Technology and Management for
Integrated Growth 2013 (RATMIG 2013)

DESIGN AND FABRICATION OF


IMPROVED BAMBOO PROCESSING
MACHINE
Er. ULHAS N. SONKUSRE1
Assistant Professor, Mechanical Engineering Department, G.N.I.E.M.
1
ulhas.sonkusre_2009@rediffmail.com
Nagpur, India

Er. P.G MEHAR2


Professor, Mechanical Engineering Department, K.D.K.C.E
2
pundlikmehar@rediffmail.com
Nagpur, India

Dr. A.V VANALKAR3


Professor, Mechanical Engineering Department ,K.D.K.C.E
3
avanalkar@yahoo.co.in
Nagpur, India

Dr. S. S KHANDARE4
Principal, Mechanical Engineering Department,VMIET
4
shashikhan@yahoo.com
Nagpur, India

Abstract

In social, economic and ecological terms bamboo is one of the non-timber forest products of the developing countries, especially
in Asia. Therefore numerous technologies being developed for the processing of the bamboo for the production of several bamboo
products .Some of these technologies have remained unmodified over long periods of time, while others have seen alterations to suit
changing requirements.

The traditional processes which are carried out on six different machines from cutting of bamboo, splitting ,knot removing, slicing,
stick length setting, and polishing. For all this lot of time consumed, cost increases as different machines used, labour cost increases
etc.

Now we are trying to minimize all these processes in a single machine, less labour cost, less time, and increasing desired output at low
cost.

KEYWORDS: Stick length setting, Cutting of bamboo, splitting, knot removing, slicing, polishing

1. INTRODUCTION
Initial treatment to raw bamboo before ready for actual work is called bamboo processing which includes
cutting ,splitting, external and internal knot removing, stick length setting etc .Bamboo and Bamboo splits are used as
fencing material and for making various types of tool handles ,ladders and scaff holding. Splits as well as slivers are used to
make a wide range of product such as basket, the core of incense sticks, kites and toys, flutes and large number of handicraft
items. it is also used to make cage for poultry, drying, packaging and transport of grains. Bamboo splits are woven into mats
and use to manufacture mat boards.

Organized By: GNI Nagpur, India


International Journal of Application or Innovation in Engineering & Management (IJAIEM)
Web Site: www.ijaiem.org Email: editor@ijaiem.org, editorijaiem@gmail.com
ISSN 2319 - 4847
Special Issue for National Conference On Recent Advances in Technology and Management for
Integrated Growth 2013 (RATMIG 2013)

2. OBJECTIVES
Presently for all processing of bamboo, individual machines are available. The main theme involved in this
work is to design and fabricate a machine with especially of multiple operation of bamboo processing in a single machine.
The design involves a new concept of bamboo processing machine with multiple operations with help of multipurpose die.

3. Traditional details of bamboo processing machine.


3.1 Cross Cutting Machine:
The cross cutting of bamboo includes the cutting of bamboo into required size so that it can fit into
splitting machines .This is done due to the varying sizes of bamboo.

Fig. 3.1

3.2 Splitting Machine:


This machine is used for splitting of bamboo into number of equal parts it depends upon the module of die it
might of four or six equal parts and so on…

Fig.3.2

3.3 Knot Removing Machine:


For removing the internal and external knots present on the joints of bamboo.

Fig .3.3

Organized By: GNI Nagpur, India


International Journal of Application or Innovation in Engineering & Management (IJAIEM)
Web Site: www.ijaiem.org Email: editor@ijaiem.org, editorijaiem@gmail.com
ISSN 2319 - 4847
Special Issue for National Conference On Recent Advances in Technology and Management for
Integrated Growth 2013 (RATMIG 2013)
3.4. Slice Making Machine:
To make the slice of ¼ or 1/6 part of split bamboo to get desired thickness of stick.

Fig .3.4
3.5. Stick Length Setting: For setting the length of sticks.

Fig .3.5

4. MODIFIED BAMBOO PROCESSING MACHINES


The modified bamboo processing consists of the following components.
 Hydraulic machine frame
 Hydraulic Double acting actuator
 Hydraulic pump
 Ac motor
 Direction control valve
 Check valve
 Pressure gauge
 Pressure relief valve
 Oil reservoir
 Multipurpose die with housing
4.1 CONSTRUCTIONAL LINE DIAGRAM AND ACTUAL MACHINE

Fig 4.1

Organized By: GNI Nagpur, India


International Journal of Application or Innovation in Engineering & Management (IJAIEM)
Web Site: www.ijaiem.org Email: editor@ijaiem.org, editorijaiem@gmail.com
ISSN 2319 - 4847
Special Issue for National Conference On Recent Advances in Technology and Management for
Integrated Growth 2013 (RATMIG 2013)
THE MAIN FOCUSES ON DIE, TO TAKE VARIETITIES OF DESIRED PRODUCT LIKE INSENSE STICS, ICE
CREAM STICS. SO WE NEED TO DEVELOPE TYPES OF DIE FOR DESIRED PRODUCT.
5. FOCUS ON MULTIPURPOSE DIE
5.1 INTRODUCTION
Die is the machining element which is one of the most important and essential element in the field of
bamboo processing machine. Die is used to break down the bamboo (raw material) and convert it into finish product such as
tooth pick, ice-cream etc.

5.2. CONSTRUCTION
Die is made of three tool plates which are placed inside the single housing. This plates are kept as one by one
inside the housing so that right from splitting to the end of finish product can be achieved.

1) HOUSING:-
It’s one of the robust hollow shaped bar. We have to place it outside the tool plates which covers & gives
support to the plates. This housing is fixed to the machine below the actuator in certain distance. After that introduce plates
one by one in reverse sequence which makes a complete die.

Fig. 5.2.1
2) FIRST TOOL PLATE:-
There are 8 cutting tools are arranged vertically in an angle and welded to the middle spindle as well as the
plate. These cutting tools are used to cut/ split the bamboo in 8 equal parts vertically and then allow to feed to the next tool
plate.

FRONT BACK
Fig 5.2.2
3) SECOND TOOL PLATE:-
In this 5 tools are arranged horizontally like steps in 1/8th part of the circle. This tool will cut the bamboo in
slicing (means thickness is far less than the width) and then allow feed to the last tool plate.

6. TOOL GEOMETRY

Fig 4.4. VARIOUS TOOLS

Organized By: GNI Nagpur, India


International Journal of Application or Innovation in Engineering & Management (IJAIEM)
Web Site: www.ijaiem.org Email: editor@ijaiem.org, editorijaiem@gmail.com
ISSN 2319 - 4847
Special Issue for National Conference On Recent Advances in Technology and Management for
Integrated Growth 2013 (RATMIG 2013)
7. HYDRAULIC CIRCUIT

 Injection cylinder
 Pilot Check Valve
 Direction Control Valve
 Return Line Filter With Bypass Check
 Fixed Displacement Pump
 Filter or Strainer
 Breather Filter
 Pressure Relief Valve
 Reservoir
 Pressure Gauge

8. MACHINE COMPONENT
8.1 Ac Motor
01 Speed 2200 RPM
02 Power 1.5 HP
03 Torque 4.786 Nm.

8.2 Oil Tank

01 Capacity 10 lit.
02 Oil used Engine oil

8.3 Hydraulic Actuator


01 Length 190mm
02 Plunger dia. 25mm

9 FORCE CALCULATION
Selection parameter of actuator
Pressure (p) =force (f) / area (a)
Min. Pr. Required (p) = 6.867 m .pa
Weight applied for complete breakage = 3455.55 n
(f = 6.670 × 518.07 = 3455.55 n)
P = force/area
A= 3455.55 / 7
= 503.211 (mm2)
A = π/ 4× d2
503.211 = 3.141 / 4 × d2
d = 25.31 mm. from data book ( appendix ii)
std. Dia. = 28 mm.

Organized By: GNI Nagpur, India


International Journal of Application or Innovation in Engineering & Management (IJAIEM)
Web Site: www.ijaiem.org Email: editor@ijaiem.org, editorijaiem@gmail.com
ISSN 2319 - 4847
Special Issue for National Conference On Recent Advances in Technology and Management for
Integrated Growth 2013 (RATMIG 2013)

Bamboo Inner Dia. Outer Dia. Area Pressure Applied Force


2
No. (Mm) (Mm) (Mm ) (M Pa) (N)

1. 11.45 28.12 518.07 6.670 3455.55

2. 13.37 30.25 578.29 6.670 3857.21

3. 31 51 1288.05 6.867 8845.06

4. 32.07 52.07 1321.66 6.867 9075.89

5. 38 58 1507.96 6.867 10355.19

Force = Pressure × Area


Forces
1. F = 6.670 × 518.07 = 3455.55 N
2. F = 6.670 ×578.29 = 3857.21 N
3. F = 6.876 × 1288.05 = 8845.06 N
4. F = 6.867 × 1321.66 = 9075.89 N
5. F = 6.867 × 1507.96 = 10355.19 N

10. ADVANTAGE
 Low capital cost.
 Low labour cost.
 Time reducing capacity.
 Less space required.
 Less material handling cost.
 Less skilled worker required.
 Operating cost is low.
 Reduce the consumption of electric. Energy.
 Minimize the idle time during the processes.

CONCLUSION
Comparison between conventional machine and improved machine

Sr. no. Criteria Conventional machine Modified machine

Working medium Mechanical system Hydraulic system


1
Installation cost High initial Low initial
2
Production time More time Less time
3
Labour cost High low
4
Accuracy in operation Moderate Moderate
5
Reservoir No need of reservoir Require pump and reservoir
6
Maintenance Complex and time consuming Easier and quicker
7

Organized By: GNI Nagpur, India


International Journal of Application or Innovation in Engineering & Management (IJAIEM)
Web Site: www.ijaiem.org Email: editor@ijaiem.org, editorijaiem@gmail.com
ISSN 2319 - 4847
Special Issue for National Conference On Recent Advances in Technology and Management for
Integrated Growth 2013 (RATMIG 2013)
FUTURE SCOPE

 To increase the bamboo cutting length, we have to increase the actuator length and increase spacing between plunger and
die housing.
 To increase the applied pressure, we can simply increase the fluid flow using direction control valve.
 As per product requirement we can use various types of tool plates. Such as, for ice cream sticks we use two tool plates and
for incense sticks making we use three tool plates.
 According to the diameter of bamboo, we can change the diameter of die and thus housing.
 If we increase the diameter of die hence we have to increase distance form frame to centre of die as well as centre of the
actuator.
 By providing the polish bath instead of collector, we direct get the polished product.

REFERENCES
 Mr.Ranjeet Kumar et it, book “DESIGN OF A COMPREHENSSIVE BAMBOO PROCESSING” Student of M.Tech
( MED), Priyadarshini College of Engineering, Nagpur, India..PP , PP.51-54
 Mr. Ramanuja Rao Principal Scientist, INBAR book “Local Tools and Equipment Technologies” PP. 110-150
 Mr. Cherla B. Sastry,Director, INBAR book “bamboo production technology” PP 130-137
 Mc-Graw–Hill Publishing Co. Ltd., New York, P.P.: - [639],[666],[638],[639], 1988.

AUTHOR
 ER. ULHAS N SONKUSRE, ASISSTANT PROFESSOR, MECHANICAL ENGINEERING, GNIEM
DAHEGAO, NAGPUR.

 Er. P.G MEHAR, PROFESSOR, MECHANICAL ENGINEERING, KDKCE , NAGPUR.

 Dr. A.V VANALKAR , PROFESSOR , MECHANICAL ENGINEERING , KDKCE , NAGPUR

 Dr. S.S KHANDARE , PRINCIPAL , VMIET WARDHA ROAD, NAGPUR

Organized By: GNI Nagpur, India