Journal Journal

of Applied
Appl Journal of Applied Horticulture, 25(1): 104-109, 2023 Horticulture
https://doi.org/10.37855/jah.2023.v25i01.18 ISSN: 0972-1045

Design of dry coconut (Cocos nucifera L.) dehusking and

deshelling machine components using solidworks simulation

V.A. Naliapara*, V.M. Sejani and N.U. Joshi

Department of Processing and Food Engineering, College of Agricultural Engineering and Technology, Junagadh
Agricultural University, Junagadh – 362001 (India). *E-mail: [email protected]

Abstract
The main objective of this study was to develop a conceptual automated solution for the labour-intensive processes of coconut
dehusking and deshelling. This was achieved by utilizing simulation-based design techniques. The study centred on the utilization of
Computer-Aided Design (CAD) as a fundamental tool for the visualization and simulation of the proposed mechanisms. This study
has developed a comprehensive framework for assessing the potential feasibility of the simulated dehusking and deshelling processes
by conducting thorough evaluations that encompass stress, displacement, strain, and safety considerations. The cylindrical design with
spiral spikes was designed to remove husks efficiently. CAD helped to comprehend the mechanism’s behavior, and subsequent analyses
revealed that stress levels remained far below acceptable thresholds. The displacement and strain effects were negligible, providing the
structural integrity of the simulated dehusking procedure. The design utilized strategically placed metal bars to improve contact points
and effectiveness. The simulation-based assessments replicated the dehusking evaluations, confirming that stress, displacement, and
strain remained within limits. This study shows that simulated automation in coconut processing has excellent potential and supports
its real-world implementation. Computer-aided design (CAD) and thorough analyses ensured the safety and reliability of conceptual
mechanisms and set a precedent for agricultural processing machinery. This study proposes a systematic approach to coconut processing
that might change the industry by improving productivity and reducing manual labour.
Key words: Coconut dehusking, Solidworks simulation, mechanical properties, design optimization, horticultural automation, safety
and efficiency

Introduction capabilities enable designers to subject their creations to diverse

load scenarios, thereby validating the design’s robustness. This
Coconuts (Cocos nucifera L.) hold paramount significance in simulation provides crucial insights into the performance of
horticultural plants, given each plant part’s multifaceted utility. machine components under varying external forces, predicting
Amid a spectrum of applications encompassing food, fibre, fuel, potential points of failure and ensuring the suitability of materials.
and structural components, the predominant role of coconuts
lies in serving as a vital food source. The pivotal core, housing These principles find validation in prior research efforts of
the coveted coconut meat, contributes to essential products such Venkataramanan et al. (2014) who undertook the design of an
as oil, chips, and milk (Asha Monicka et al., 2021). However, automated coconut dehusking machine, wherein measurements
harnessing this potential hinges on the prerequisite task of of required forces informed component design, executed in 3D
extracting the coconut meat, necessitating the removal of both the through Solidworks software. Subsequent simulation assessments
husk and shell. Although time-honoured, this traditional approach using ANSYS WORKBENCH v12.0 validated its performance
of manual dehusking and deshelling presents challenges of labour under diverse load conditions. Jakasania et al. (2017) extended
intensiveness and jeopardizes worker safety by exposing them to this approach through finite element analysis of an inclined
potential injuries (Mishra and Mohanty, 2016). To address these subsoiler, with CAD-based simulations facilitating optimized
concerns, the integration of machinery emerges as a possible design and replacing extensive field testing. Rustam et al.
solution. (2022) reinforced the significance of CAD in machinery design,
demonstrating its applicability in developing an electric sugarcane
In light of these imperatives, the current study has embarked on
cutter through Finite Element Analysis.
a comprehensive endeavour – designing and conceptualizing a
machine adept at dehusking and deshelling dry coconuts. The This research embarks on designing a simulated dry coconut
formulation of this machinery draws upon critical physical and dehusking and deshelling machine, with CAD and simulation
mechanical properties of coconuts, encompassing parameters analysis forming the cornerstones of innovation. By leveraging
such as size, thickness, as well as forces essential for husk these tools, the study endeavours to enhance the efficiency, safety,
removal and shell breaking (Naliapara et al., 2021). In this and overall functionality of coconut processing machinery.
endeavour, the potential of Computer-Aided Design (CAD)
Material and method
shines through. As a versatile tool, CAD expedites the machinery
design process. The tool’s prowess in 3D modelling enhances The following data was obtained from earlier research (Naliapara
operational clarity and visualization. Moreover, CAD’s simulation et al., 2021) on dry coconuts, and is presented in Table 1 and 2.
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 Design of dry coconut dehusking and deshelling machine components using solidworks simulation 105

Two main types of forces were used to determine the machine’s

power requirements and validate the components’ design: husk
removal force and shell-breaking force.
Table 1. Husk separation force values for dry coconut at various intervals
Parameter Force (kN) Average
1 2 (kN)
Force at shell and husk joint 1.87 1.85 1.86
Force at middle of shell and husk surface 1.01 0.99 1.00
(approx. 30% from shell)
Force near husk surface (approx. 60% 0.75 0.78 0.76
from shell)
(Naliapara et al., 2021)
Design of dehusking unit: While designing the dehusking
mechanism, two key factors were considered: (a) the mechanism
should remove the husk through a peeling action, and (b) the pair
of dehusking rolls should be large enough to accommodate the
maximum size of dry coconuts. To achieve the peeling action,
it was considered to have a spiral of spikes around a cylinder.
The diameter of the dehusking rolls was based on the size of
dry coconuts, which was found to be an average of 134.07 mm
(Naliapara et al., 2021). However, for design purposes, a size of
155 mm was considered to allow for a margin of error. The rolls
should have dimensions to accommodate that size of coconut
while dehusking. The combined diameter of two dehusking rolls
should be greater than the size of a large size coconut. Considering
these factors, the cylinder of 89 mm diameter was selected as the
base of dehusking roll. The length of dehusking cylinder was
decided to be around thrice the length of large-size coconuts (200
mm) to give proper time for the complete dehusking of coconut.
The length of the dehusking cylinder was kept as 620 mm. The
spiked spiral was made from edge of sprockets. The sprockets
were cut in half and the hub portion of the sprockets was then Fig. 1. Designed dehusking roll
removed. The remaining edge of sprocket (12 mm+ around 1-2
coconut shells of various sizes. It was assumed that increasing the
mm of weld) was bent and weld on cylinder at 100 mm pitch
gap between rolls could facilitate coconut shells of small to large
(final dia. 115 mm). A shaft of 25 mm diameter was welded
size. To make converging or cone-type cylinders is somewhat
through whole cylinder to provide strength, support and drive to
difficult. So, fixed-sized cylinders were selected and metal bars
the dehusking cylinder (Fig. 1).
were cut in trapezoidal sections with edges cut in them and
Table 2. Dry coconut shell breaking force values attached at the cylinders’ periphery. The metal bars were cut and
arranged so that one bar had a peak or edge on the periphery, and
Sr. no. Force (kN)
the next bar had a gap. The alternative arrangement increases the
1 4.0 contact points on the coconut shell (Fig. 2).
2 2.0
Force acting on dehusking roll: The function of the dehusking
3 2.0
roll is to remove the husk through a tearing action that results in
4 4.0 peeling the husk from the coconut. The main force component
5 4.2 responsible for that action would be torque. To remove the dry
6 4.5 coconut husk by tearing action with a peeling effect would be
0.78 kN ≈ 0.8 kN. And the radius of dehusking roll is 57.5 mm.
7 2.2
This would result in torque:
8 3.5
T=F×r
9 3.8
T = 0.8 × 57.5
10 2.7 T = 46 Nm
Average 3.29 To remove husk from dry coconut, the roll should exert 46 Nm
SD 0.97 torque thus it should be able to withstand 46 Nm torque when
(Naliapara et al., 2021) in operation.
Design of the deshelling unit: The deshelling cylinder size Also, assuming that at any time two points of peripheral spikes
should be large enough to allow maximum points to come in would be in contact with the coconut husk during simulation,
contact with the coconut shell. To achieve that, the overall the torque applied on the dehusking roll would have two contact
diameter of the deshelling roll should be greater than the diameter points on peripheral spikes. The shaft that is passing through the
of the dehusked coconut. Also, the pair of rolls should break the dehusking roll would be kept fixed during the study.
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106 Design of dry coconut dehusking and deshelling machine components using solidworks simulation

called meshing. Finite element analysis programs look at the

model as a network of interconnected elements and solve the
applied load’s effect basis on these small interconnected elements.
Simulation study of dehusking unit: The main supporting shaft
passing through the dehusking cylinder was considered a fixed
geometry member. The shaft was the main supporting member of
the whole dehusking cylinder assembly. The shaft material was
proposed as AISI 1020 steel. For placement of external loads,
it was assumed that the coconut would encounter at least two
peripheral teeth during the dehusking operation. Also, the mid-
section of anybody might be most susceptible to failure as the
external load is applied to it. Two peripheral teeth were selected
around the middle of the whole assembly as an external toque was
applied during the dehusking operation. Meshing is one of the
most important components of any simulation analysis as it breaks
down the whole component into smaller manageable components
for analysis. Solidworks lets users adjust the quality of meshing
for the desired purpose. The highest meshing quality was selected
for this analysis to get more accurate results. The materials
proposed for constructing the dehusking unit components and
their mass density and yield strength are listed in Table 3. The
fixture, applied load, and mesh model are shown in Fig. 3.
Simulation study of deshelling unit: It was assumed that the
Table 3. Proposed materials for construction of dehusking unit and their
properties
Material Associated part Mass Yield
density strength
(kg/m3) (N/mm2)
Galvanized Main base cylinder (no. 1 in 7870 203.94
Fig. 2. Designed deshelling roll Steel Fig. 1)
Cast carbon End caps of cylinder (no. 2 in 7800 248.16
Force acting on the deshelling roll: The function of the steel Fig. 1)
dehusking roll would be to break the coconut shell while rotating. AISI 1020 Main supporting shaft through 7900 351.57
cylinder (no. 3 in Fig. 1)
According to UTM testing done by Naliapara et al., 2021, the
AISI 1045 Peripheral teeth for husk 7850 530
force required to break the coconut shell would be 4.5 kN, and tearing (no. 4 in Fig 1)
the radius of the deshelling roll was 90 mm. The resulting torque
to be:
T=F×r
T = 4.5 × 90
T = 405 Nm
To break open the coconut shell, the deshelling roll would exert
405 Nm force thus, it should be able to withstand 405 Nm during
operation.
Assuming that two spike blades would come in contact with the
coconut shell during the deshelling operation. Also, the main
supporting shaft passing through the cylinder would be kept fixed
during simulation evaluation.
Simulation study
In the simulation process using Solidworks software, there are
three key parameters to consider: 1) fixture, 2) placement of
external loads, and 3) meshing. The fixture defines the given
body’s movement characteristics. In this case, both the assemblies
were given fixed geometry fixtures. The placement of the external
load is important because it determines where the applied force Fig. 3. Mesh model, Fig. 4. Mesh model, fixed member
fixed member (by green (by green narrows) and applied
will act, and the overall behaviour of the simulated system under narrows) and applied torque (indicated by blue arrows) in
the applied force will depend on the location of the load. The torque (indicated by pink deshelling roll
process of dividing the simulated object into smaller pieces is arrows) in dehusking roll

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 Design of dry coconut dehusking and deshelling machine components using solidworks simulation 107

Table 4. Proposed materials for construction of the deshelling unit and

their properties
Material Associated part Mass Yield
density strength
(kg/m3) (N/mm2)
Galvanized Steel Main base cylinder (no. 1 in 7870 203.94
Fig. 2)
Cast carbon steel End caps of cylinder and 7800 248.16
peripheral teeth for shell
breaking (no.2, 3 and 4 in Fig.
2)
AISI 1020 Main supporting shaft through 7900 351.57
cylinder (no. 5 in Fig. 2)

deshelling unit might encounter higher stress due to the nature

of the operation. The shell-breaking process requires more force
than the dehusking unit, so the components of the deshelling unit
subassembly were designed to be stronger and more durable. The
thicker main supporting shaft passes through the selected fixed
geometry member in the deshelling unit. In the deshelling unit,
the peripheral toothed blades would come in contact with coconut
shells; thus, two rows of teeth were selected for external load
application. Like the dehusking unit, the highest meshing quality
was selected for more accurate results. The fixture applied load Fig. 5. Stress distribution in Fig. 6. Displacement in
dehusking roll dehusking roll
and mesh model are shown in Fig. 4, and the proposed materials
to build the deshelling unit components is given in Table 4 with dehusking roll. So, based on this resultant data, it can be said that
their mass density and yield strength. the design and material selection of the dehusking roll were safe.
Result and discussion Strain: The value of strain obtained as the result of the analysis
This section discusses the report generated by solidworks and was 0.00016, which can be considered negligible, and thus, the
the component’s response to the force applied on them. The design could be regarded as safe for operation (Fig. 7).
four resultant components are discussed: 1) Stress distribution, Factor of safety : The resultant factor of safety was observed as
2) Displacement, 3) Strain distribution and 4) Factor of safety. 5.21 minimum (Fig. 8). The observed factor of safety value can
Finite element analysis result of dehusking roll be generally considered as safe.

Stress distribution in dehusking roll: As per data presented in

Table 5 the maximum stress observed at the end of the analysis
was 37.71 N/mm2 (MPa). The stress value should be less than
the yield strength of the weakest material used in component
making. The majority of stress distribution was observed on (Fig.
5) blade component where the coconut surface would touch it
during dehusking, the nearby region of contact on the base roll
and on the shaft – base roll contact. For the dehusking roll, the
minimum yield strength was observed in main base cylinder’s
galvanized steel, 203.94 N/ mm2 (MPa). The stress observed
during analysis (37.71 N/mm2 (MPa)) is less than the yield
strength of the material. According to this data, the design and
material selection of the dehusking roll were safe on stress basis.
Table 5. Finite element analysis result of dehusking roll
Name Type Min Max
Stress VON: von Mises Stress - 37.71 N/mm2
(MPa)
Displacement URES: Resultant Displacement - 0.0087 cm
Strain ESTRN: Equivalent Strain - 0.00016
Factor of Safety Automatic 5.21 -
Displacement: Displacement of machine parts causes the
machine to function with error and reduces its efficiency, or
sometimes it may lead to failure of the machine (Fig. 6). In the
case of the dehusking roll, the displacement was observed as
0.0087 cm = 0.087 mm. The resultant displacement is negligible
Fig. 7. Strain distribution in Fig. 8. Factor of safety distribution
compared to the length (950 mm) and diameter (115 mm) of the dehusking roll in dehusking roll

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108 Design of dry coconut dehusking and deshelling machine components using solidworks simulation

Finite element analysis result of deshelling rollstress mm) of the deshelling roll (Fig. 10). So, based on this resultant
distribution in deshelling roll: As per data presented in Table data, it can be said that the design and material selection of the
6 the maximum stress observed at the end of the analysis was deshelling roll were safe.
91.5 N/mm2 (MPa). The stress value should be less than the yield
Strain: The value of strain obtained as the result of the analysis
strength of the weakest material used in component making. The
was 0.00042 (Table 6), which can be considered negligible, and
majority of stress distribution was observed on (Fig. 9) blade
thus, the design could be considered safe for operation (Fig. 11).
component – main base cylinder contact where the coconut
surface would touch it during deshelling and on the shaft–base Factor of safety: The resultant factor of safety was observed
roll contact. For the deshelling roll, the minimum yield strength as 2.43 minimum (Table 6 and Fig. 12). The observed factor of
was observed in the main base cylinder’s galvanized steel, 203.94 safety value can be generally considered as safe.
N/ mm2 (MPa). The stress observed during analysis (91.5 N/mm2
In summary, this research focuses on the simulated design of
(MPa)) is less than the yield strength of the material. According
a dry coconut dehusking and deshelling machine, leveraging
to this data, it can be said that the design and material selection
Computer Aided Design (CAD) and simulation analysis. By
of the deshelling roll were safe on a stress basis.
incorporating essential coconut properties and CAD modelling,
Table 6. Result of simulation values for deshelling roll the research enhances visualization, while simulation analysis
Name Type Min Max provides insights into component performance under varying
Stress VON: von Mises Stress - 91.5 N/mm2 loads, minimizing failure risks and ensuring material suitability.
(MPa) Preceding research, such as automated dehusking designs and
Displacement URES: Resultant - 0.0065 cm
CAD-driven simulations, reinforces the study’s methodology.
Displacement
Strain ESTRN: Equivalent Strain - 0.00042 Overall, this work contributes to the development of a simulated
Factor of Safety Automatic 2.43 - machine, promising improved efficiency and safety in coconut
Displacement: In dehusking roll, the displacement was observed processing through innovative design and simulation techniques.
as 0.0065 cm = 0.065 mm (Table 6). The resultant displacement
is negligible compared to the length (250 mm) and diameter (180

Fig. 9. Stress distribution in deshelling roll Fig. 10. Displacement in deshelling roll

Fig. 11. Strain distribution in deshelling roll Fig. 12. Factor of safety distribution in deshelling roll

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 Design of dry coconut dehusking and deshelling machine components using solidworks simulation 109

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2016, Department of Industrial and production engineering, Dr B Received: December, 2022; Revised: January, 2023; Accepted: February, 2023
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