ADDIS ABABA SCIENCE AND TECHNOLOGY

UNIVERSITY

COLLEGE OF ELECTRICAL AND MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DESIGN, ANALYSIS AND SIMULATION OF PLASTIC

CRUSHER MACHINE

A Thesis Submitted in Partial Fulfillment of the Requirements for

the Degree of Bachelors of Science in Mechanical Engineering

By

Waseneh Mulu Kibret

Wubliker Esubie Melesse

Yohannes Gebremedhihn Tesfay

Thesis Advisor: Mr. Desalegn Abera (MSc)

Kirubel Amsalu(co-advisor)
ADDIS ABABA, ETHIOPIA
January, 2021

III
 Approval

ADDIS ABABA SCIENCE AND TECHNOLOGY UNIVERSITY

COLLEGE OF ELECTRICAL AND MECHANICAL ENGINEERING

DEPARTMENT OF MANUFACTURING ENGINEERING

Design, analysis, and simulation of plastic crusher machine

Submitted by: Student name Signature Date

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Approved by:

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Thesis Advisor Signature Date

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Examiners Signature Date

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Head of Dept. Signature Date
 Declaration

We hereby declare that we carried out the work reported in this thesis entitled
“DESIGN, ANALYSIS AND SIMULATION OF PLASTIC CRUSHER MACHINE”
in the department of Mechanical Engineering, Addis Ababa Science and Technology
University, under the supervision of our advisor Mr. Desalegn Abera and co-advisor
Mr. Kirubel Amsalu. Our paper was best determined attempt strenuous exertions to
make it easy to read and understand. We solemnly declare that to the best of our
knowledge; no part of this thesis project has been submitted here or elsewhere in a
previous application for the award of a BSc. Thesis project. All sources of a
knowledge used have been duly acknowledged.

Submitted by: signature date

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 Acknowledgement

First of all, we would like to thank to our almighty God for helping us in the
successful
accomplishment of this project paper. We want to express our gratitude to Addis
Ababa Science & Technology University Department Mechanical Engineering for the
establishment of progressive project evaluation within students and academic advisors
periodically.

we would like to forward our special thanks to Mr. Desalegn Abera for his grateful
assistance and advice that brings our project to success, and constructive ideas
throughout our work. The last but not the least, our acknowledge extends to express
our heartfelt appreciation and gratitude to our co-advisor, Kirubel Amsalu for his
invaluable advice, continuous support, encouragement, valuable guidance, ingenious
and constructive suggestion throughout the project study.

III
 Abstract

High urbanization rates and changes in the life styles and steady rise in living
standards have resulted in the increase of solid waste both in type and volume. The
rapid growth of spring water industry, trade and services has accelerated the
generation of plastic bottles. Now a days the plastic is one of the most used material
in world wide. The advantage of using plastics produced from polyethylene
terephthalate (PETs) include bottles in packaging water, soft drinks, soda etc.
However, they are nonbiodegradable and can stay unchanged for as long as
4500years on earth causing menace to our lands, streams and drainage systems.
Plastic waste accounts for more than serious of the municipal solid waste stream in
our country. The problem of plastic waste is not only limited to Ethiopia rather it is a
worldwide phenomenon. The world’s annual consumption of plastic materials has
increased from around 5 million tons in the 1950’s to more than 100 million tons;
thus, twenty (20) times more plastic is produced today than in the past fifty (50) years
ago. This simply means that more resources are being used to meet the increased
demand for plastic, thus, more plastic waste is being generated.

As a result, the Use of plastic is increasing day to day life in present scenario which
cause a serious environmental issue, for this problem we need to make eco-friendly
environment by recycling possible waste plastic. To solve this issue already exist
highly operated machines but they are too costly and not easily available. so, the
main purpose of our project is to design cost-effective plastic crusher/cutter machine,
the use of power supply and single shaft mechanism which can be useful for Micro,
Small & Medium Enterprises. To implement this concept plastic crushing machine
implemented which consists some mechanical & electrical components like Frame,
hopper, electric motor, V-belt drive System, crushing setup. This machine is used for
cutting the plastic in to small pieces, which are in irregular shaped flakes which can
be processed further Recycle recovers the raw material, which helps to make new
plastic product. Recycled plastic pieces are fed in to extrusion machine where it can
form wire like plastic called filament and further used in 3D printing machine.

IV
Key words: Plastic, Plastic recycling, Crusher machine

V
TABLE OF CONTENTS

Approval.........................................................................................................................I
Declaration....................................................................................................................II
Acknowledgement........................................................................................................III
Abstract........................................................................................................................IV
List of Tables.............................................................................................................VIII
List of Figures..............................................................................................................IX
Abbreviations/acronyms.............................................................................................XII
CHAPTER ONE............................................................................................................1
1. INTRODUCTION..................................................................................................1

1.1. Background.......................................................................................1

1.1.1. Historical timeline of plastics........................................................2

1.2. Problem Statement............................................................................7

1.3. Objective...........................................................................................9

1.3.1. Main Objective..............................................................................9

1.3.2. Specific Objective.........................................................................9

1.4. Scope of the project..........................................................................9

1.5. Significance of the project................................................................9

1.6. Methodology...................................................................................10

CHAPTER TWO.........................................................................................................12
2. LITERATURE REVIEW.....................................................................................12

2.1. Historical Development of plastic crusher machine.......................12

2.2. Advantages of Recycling Plastics...................................................13

2.3. Working principle...........................................................................14

2.4. Previous work related with plastic cutter........................................17

CHAPTER- THREE....................................................................................................21
3. CONCEPTUAL DESIGN....................................................................................21

VI
 3.1. List of Customer requirements.......................................................21

3.2. Organizing customer requirements.................................................23

3.3. Establishing function structure.......................................................25

3.4. Product specifications.....................................................................26

3.5. Quality Function Deployment method (QFD)................................28

3.6. Concept Generation........................................................................30

3.6.1. Developing working structures....................................................30

3.6.2. sketch assembly of alternatives...................................................32

3.7. Concept selection/evaluation..........................................................34

3.7.1. Pugh’s evaluation matrix.............................................................34

CHAPTER FOUR........................................................................................................36
4. EMBODIMENT DESIGN...................................................................................36

4.1. Product definition...........................................................................36

4.2. Assemble method............................................................................39

4.3. Manufacturing method....................................................................39

4.4. Working principle...........................................................................41

4.5. Maintenance/Design for Maintainability........................................41

CHAPTER FIVE..........................................................................................................43
5. DESIGN ANALYSIS..........................................................................................43

5.1. Electrical Motor Selection..............................................................43

5.2. Design of Belts and pulleys............................................................46

5.2.1. Design of V – belt 1.....................................................................47

5.2.2. Design of V – belt 2.....................................................................54

VII
 5.3. Design of Crushing Roll Shaft........................................................56

5.4. Design of Spur Gear.......................................................................66

5.5. Design of Main Shaft......................................................................72

5.6. Design of shaft between two pullies...............................................78

5.7. Bearing Selection............................................................................81

5.8. Design of Hopper............................................................................84

5.9. Design of Fasteners.........................................................................84

5.9.1. Design of Key..............................................................................84

5.9.2. Design of Bolt and Nut................................................................87

5.10. Design of Frame..............................................................................89

5.11. Design of Sieve...............................................................................92

CHAPTER SIX............................................................................................................93
6. PRODUCT DEVELOPMENT ECONOMICS....................................................93

6.1. Machining Costs.............................................................................93

6.1.1. Component Cost:.........................................................................93

6.2. Assembly Cost................................................................................95

6.3. Machining/ Manufacturing Cost.....................................................95

6.4. Design Cost.....................................................................................96

6.5. Total Cost of Complement..............................................................97

CHAPTER SEVEN......................................................................................................98
7. RESULT AND DISCUSSION............................................................................98

7.1. Result..............................................................................................98

7.2. Discussion.....................................................................................104

VIII
CHAPTER EIGHT.....................................................................................................105
8. CONCLUSION AND RECOMMENDATION.................................................105

8.1. Conclusion....................................................................................105

8.2. Recommendation..........................................................................106

REFERENCE.............................................................................................................107
APPENDIX................................................................................................................110

IX
 List of Tables

Table 2. 1: Cutting machine comparison…………………………………………..………

16

Table 2. 2: mission statement…………………………………………………………..……

16

Table 3. 1: list of customers requirement.………………………….………………..…….

22

Table 3. 2: Performance-specification method…………………….………….………….

27

Table 3. 3: morphological chart……………………………………………………..………

31

Table 3.4: Pugh’s evaluation matrix…………………………………………………….....

35

Table 5. 1: motor selection evaluation………………………………………………..……

44

Table 5. 2: belt characteristics……………………………………………………….….….

53

Table 5.3: Design requirements for light, stiff roll shaft ………………………….………
64

Table 5.4: materials for roll crushing shaft using ashby chart……………………… . .
65

Table 5.5: Design of spur gear specification…………………………………….…………

71

Table 5.6: Design of shaft specification………………………………………..……….….

81

Table 5. 7: key selection and evaluation……………………………………….……..……

86

Table 5. 8: Design dimensions of screw threads, bolts and nuts………………...……...

X
88

Table 5. 9: Design Requirements for frame Legs……………………………...………..…

89

Table 5. 10: materials for frame leg……………………………………………..

……….. ..91

Table 6. 1: bill of materials plastic crushing machine……………………………..

……..94

Table 6. 2: assembly cost list……………………………………………………………...…

95

Table 6. 3: manufacturing cost…………………………………………………………...

….96

XI
 List of Figures

Figure 1.1: Ethiopia's plastic consumption 2007-

2020…………………………………….8

Figure 2. 1: list of customer requirements……………………………………………....…

15

Figure 3. 1: flow chart of customer requirements………………………………….…...…

21

Figure 3. 2: weight objective method diagram…………………………………...….

…….24

Figure 3. 3: block diagram of plastic crusher……………………………………….

……..25

Figure 3. 4: function tree……………………………………………………………….….…

26

Figure 3. 5: (a) competitive 1, (b)competitive 2, (c) competitive 3……..…………...

…..28

Figure 3. 6: concept generation………………………………………………….……….…

29

Figure 3. 7: concept alternative 1……………………………………………………….

…..31

Figure 3. 8: concept alternative 2………………………………….…………….

………….32

Figure 3. 9: concept alternative 3…………………………………………………..

……….32

Figure 3. 5: concept alternative 4……………………………………….………..………..33

Figure 4. 1: shaft………………………………………………………………………………
35

XII
Figure 4. 2: pulley……………………………………………………………………..
……...35

Figure 4. 3: (a) spur gear, (b) crushing blade, (c) hopper ……………………...
………..36

Figure 4. 4: bolt and nut ……………………………………………………………..………

36

Figure 4. 5: frame…………………………………………………..…………………………
37

Figure 4. 6: sieve/filter………………………………………………..………………………
37

Figure 4. 7: (a) key, (b) roller

bearing……………………………………………………...37

Figure 5. 1: geometry analysis of belt drive

……………………………………………….47

Figure 5. 2: speed reduction in two pulley configurations …………………..

…………..48

Figure 5. 3: deep groove pulleys geometry ………………………………….

……………..55

Figure 5. 4: processing route at catching the plastic bottle …………...…………………

57

Figure 5. 5: young's modulus density material selection …………………………………

65

Figure 5. 6: flow chart of bearing selection

………………………………………………..82

XIII
Figure 5. 7: hopper geometry …………………………………………...
…………………..84

Figure 5. 8: flow chart of key selection ………………………………….

………………….85

Figure 5. 9: key profiles………………………………………………………………………

85

Figure 5. 10: young’s modulus-density chart……………………………….

……………..91

Figure 7. 1: Equivalent (von-mises) stress of frame………………………………………

98

Figure 7. 2: Total deformation of frame ……………………………………...……………

99

Figure 7. 3: Equivalent (von-mises) stress of shaft

……………………………………….99

Figure 7. 4: Total deformation of shaft ………………………………………………..…

100

Figure 7. 5: Equivalent (von-mises) stress of gear

…………………………………….100

Figure 7. 6: Total deformation of gear ………………………………………….………

101

Figure 7. 7: Equivalent (von-mises) stress of rushing shaft with

blade…………….. ..101

Figure 7. 8: Total deformation of crushing roll shaft with welded blade ……………
102

Figure 7. 9: Equivalent (von-mises) stress of

pulley…………………………………….102

Figure 7. 8: Total deformation of pulley

………………………………………………..103

XIV
XV
 Abbreviations/Acronyms

Symbol Definition
Au quality No
bd datum width
b1 top width
b2 face width
B width of flat belt
 arc of contact
C1 arc of contact correction factor
C2 load factor
C3 length factor
C4 additional factors
CD center distance
CS crushing size
Cs size factor
Cgf gear proportion factor
Cpf pinion proportion factor
Cma mesh alignment
Cp elastic coefficient
CR reliability factor
dd datum diameter of a grooved pully
Dp pinion pitch diameter
Ep modulus of elasticity
Ea belt deflection
e drive center distance
f half of face width
fB flax rate
Ft transmitted load
g no of load application per revolution
HB Brinell hardness
i speed ratio

XVI
I pitting geometry
J bending geometry factor
k belt tension characteristics
KB rim thickness factor
Kf stress concentration factor
Km load distribution factor
Ko overload factor
Ks size factor
KR reliability
Ku dynamic factor
Ld datum length
M moment
MA starting torques
m Module
fos design factor (factor of safety)
Nc expected no of cycle of loading
Np number of pinion teeth
NP number of load cycle of pinion
Ng number of gear teeth
NG number of load cycle of gear
P drive power
PB design power
PN nominal power
np speed of pinion
ng speed of gear
R Roll radius
Sait Static shaft load at initial installation
Sast Static shaft load at retention
Sadyn dynamic shaft load
SF service factor
St bending stress

XVII
Sy yield stress
T tension
T Torque
V belt speed
VR velocity ratio
W weight of drive
X radial factor
Y thrust factor
YNp bending stress cycle of pinion
YNg bending stress cycle of gear
Z no grooves
Z no belt
ZNp Pittong stress cycle of pinion
ZNg No of load cycle of gear

XVIII
 CHAPTER ONE

1. INTRODUCTION

.1. Background

Waste (or wastes) are unwanted or unusable materials. Waste is any substance which
is discarded after primary use, or is worthless, defective and of no use. A by-product
by contrast is a joint product of relatively minor economic value. A waste product
may become a by-product, joint product or resource through an invention that raises a
waste product's value above zero. Examples include plastics, municipal solid waste
(household trash/refuse), hazardous waste, wastewater (such as sewage, which
contains bodily wastes (feces and urine) and surface runoff), radioactive waste, and
others. But in this survey, we consider details about plastics [1].

The word plastic derives from the Greek πλαστικός (plastikos) meaning "capable of
being shaped or molded" and, in turn, from πλαστός (plastos) meaning "molded"[2].
The plasticity, or malleability, of the material during manufacture allows it to be cast,
pressed, or extruded into a variety of shapes, such as: films, fibers, plates, tubes,
bottles, boxes, amongst many others. Plastic is material consisting of any of a wide
range of synthetic or semi-synthetic organic compounds that are malleable and so can
be molded into solid objects. Plasticity is the general property of all materials which
can deform irreversibly without breaking but, in the class of moldable polymers, this
occurs to such a degree that their actual name derives from this specific ability.
Plastics are typically organic polymers of high molecular mass and often contain other
substances. They are usually synthetic, most commonly derived from petrochemicals,
however, an array of variants is made from renewable materials such as polylactic
acid from corn or cellulosic from cotton linters [3]. Due to their low cost, ease of
manufacture, versatility, and imperviousness to water, plastics are used in a multitude
of products of different scale, including paper clips and spacecraft. They have
prevailed over traditional materials, such as wood, stone, horn and bone, leather,
metal, glass, and ceramic, in some products previously left to natural materials.

1
 1.1.1. Historical timeline of plastics

The development of plastics has evolved from the use of natural plastic materials
(e.g., chewing gum, shellac) to the use of chemically modified, natural materials (e.g.,
natural rubber, nitrocellulose, collagen, gilalite) and finally to completely synthetic
molecules (e.g., Bakelite, epoxy, polyvinyl chloride). Early plastics were bio-derived
materials such as egg and blood proteins, which are organic polymers. In around 1600
BC, Mesoamericans used natural rubber for balls, bands, and figurines [4]. Treated
cattle horns were used as windows for lanterns in the Middle Ages. Materials that
mimicked the properties of horns were developed by treating milk-proteins (casein)
with lye.

In the nineteenth century, as industrial chemistry developed during the Industrial

Revolution, many materials were reported. The development of plastics also
accelerated with Charles Goodyear's discovery of vulcanization to thermoset materials
derived from natural rubber.

Parke sine (nitrocellulose) is considered the first man-made plastic. The plastic
material was patented by Alexander Parkes, in Birmingham, England in 1856[5]. It
was unveiled at the 1862 Great International Exhibition in London [6]. Parke sine
won a bronze medal at the 1862 World's fair in London. Parke sine was made from
cellulose (the major component of plant cell walls) treated with nitric acid as a
solvent. The output of the process (commonly known as cellulose nitrate or
pyroxylin) could be dissolved in alcohol and hardened into a transparent and elastic
material that could be molded when heated [7]. By incorporating pigments into the
product, it could be made to resemble ivory.

In 1897, the Hanover, Germany mass printing press owner Wilhelm Kristie was
commissioned to develop an alternative to blackboards. The resultant horn-like plastic
made from the milk protein casein was developed in cooperation with the Austrian
chemist (Friedrich) Adolph Spitteler (1846–1940). The final result was unsuitable for
the original purpose. In 1893, French chemist Auguste Trilliant discovered the means
to insolubilize casein by immersion in formaldehyde, producing material marketed as
gilalite [8].

2
In the early 1900s, Bakelite, the first fully synthetic thermoset, was reported by
Belgian chemist Leo Baekeland by using phenol and formaldehyde.

After World War I, improvements in chemical technology led to an explosion in new

forms of plastics, with mass production beginning in the 1940s and 1950s (around
World War II) [9]. Among the earliest examples in the wave of new polymers were
polystyrene (PS), first produced by BASF in the 1930s, and polyvinyl chloride (PVC),
first created in 1872 but commercially produced in the late 1920s. In 1923, Durite
Plastics Inc. was the first manufacturer of phenol-furfural resins.[10] In 1933,
polyethylene was discovered by Imperial Chemical Industries (ICI) researchers
Reginald Gibson and Eric Fawcett. In 1954, polypropylene was discovered by Giulio
Natta and began to be manufactured in 1957 [8].

In 1954, expanded polystyrene (used for building insulation, packaging, and cups)
was invented by Dow Chemical. The discovery of Polyethylene terephthalate (PET) is
credited to employees of the Calico Printers' Association in the UK in 1941; it was
licensed to DuPont for the US and ICI otherwise, and as one of the few plastics
appropriate as a replacement for glass in many circumstances, resulting in widespread
use for bottles in Europe [7].

Plastics are usually classified by: the chemical structure of the polymer's backbone
and side chains; some important groups in these classifications are: the acrylics,
polyesters, silicones, polyurethanes, and halogenated plastics.

Other classifications are based on qualities that are relevant for manufacturing or
product design. Examples of such qualities and classes are: thermoplastics and
thermosets, conductive polymers, biodegradable plastics and engineering plastics and
other plastics with particular structures, such as elastomers.

Biodegradable plastics and bioplastics

Biodegradable plastics are plastics that degrade, or break down, upon exposure to:
sunlight or ultra-violet radiation, water or dampness, bacteria, enzymes or wind
abrasion. In some instances, rodent, pest, or insect attack can also be considered as

3
forms of biodegradation or environmental degradation. Some modes of degradation
require that the plastic be exposed at the surface (aerobic), whereas other modes will
only be effective if certain conditions exist in landfill or composting systems
(anaerobic). Some companies produce biodegradable additives, to enhance
biodegradation. Plastic can have starch powder added as a filler to allow it to degrade
more easily, but this still does not lead to the complete breaking down of the plastic.
Some researchers have genetically engineered bacteria to synthesize completely
biodegradable plastics, such as Biopol; however, these are expensive at present [9].

Bioplastics

While most plastics are produced from petrochemicals, bioplastics are made
substantially from renewable plant materials such: as cellulose and starch [12]. Due
both to the finite limits of the petrochemical reserves and to the threat of global
warming, the development of bioplastics is a growing field. However, bioplastic
development begins from a very low base and, as yet, does not compare significantly
with petrochemical production. Estimates of the global production capacity for bio-
derived materials is put at 327,000 tons/year. In contrast, global production of
polyethylene (PE) and polypropylene (PP), the world's leading petrochemical derived
polyolefins, was estimated at over 150 million tons in 2015[9].

Plastics are made up of long chain molecules called polymers. Various types of
polymers can be made from hydrocarbons derived from coal, natural gas, oil and
organic oils which are transformed into materials with desirable properties. there are
two types of plastics. Those are Thermoplastics and thermosets.

Plastics that can be readily recycled are Thermoplastics which means they will soften
when heated. The thermoplastic, unlike the other one, is made of polymer molecules
that reach high temperatures when it becomes liquid. It’s then a hard material once
cooled. These qualities make this type of plastics an easily recyclable material. Some
of the most used thermoplastic polymers are polyethylene or PVC, present in many of
the everyday packages that we use daily in our homes, but also in the production
waste of large factories. Reusing these remains of plastics for the manufacture of
other serviceable materials is a sustainable way that allows the industry to obtain

4
greater benefits.

Thermosetting Plastics harden when heated, are often used in electrical applications
and are not suitable for recycling. Thermoplastics are light, durable, moldable,
hygienic and economic, making them suitable for a wide variety of applications
including food and product packaging, car manufacturing, agriculture and housing
products.

Plastics are inexpensive, light weight and durable materials, which can readily be
molded into a variety of products that find use in a wide range of applications. As a
consequence, the production of plastics has increased markedly over the last 60 years.
However, current levels of their usage and disposal generate several environmental
problems. Around 4 % of world oil and gas production, a non-renewable resource, is
used as feedstock for plastics and a further 3–4% is expended to provide energy for
their manufacture. Recycling is one of the most important actions currently available
to reduce these impacts and represents one of the most dynamic areas in the plastics
industry today. Recycling provides opportunities to reduce oil usage, carbon dioxide
emissions and the quantities of waste requiring disposal. Here, we briefly set
recycling into context against other waste reduction strategies, namely reduction in
material use through down gauging or product reuse, the use of alternative
biodegradable materials and energy recovery as fuel. While plastics have been
recycled since the 1970s, the quantities that are recycled vary geographically,
according to plastic type and application.

Moreover, the presence of plastic wastes in the environment is considered hazardous

due to their potentials to catch fire easily. It also has negative effect on arable soil
especially for farming purpose. Consequently, action should be taken to promote
recycling of plastic bottles. According to Oseni [11], plastics which typically
exemplifies PET bottles are more or less non-biodegradable as they remain
undecomposed in the ground for several thousands of years. Recycling is an aspect of
environmental engineering that deals with the development of technically reasonable
solutions to environmental problems which may involve designing a sustainable
approach that can convert waste materials to useful items, thereby, avoiding the use of
virgin raw materials which depending on the production process may constitute high

5
level of environmental pollution, require high energy input and huge cost of
production [9].

Recycling of packaging materials has seen rapid expansion over the last decades in a
number of countries. Advances in technologies and systems for the collection, sorting
and reprocessing of recyclable plastics are creating new opportunities for recycling
and with the combined actions of the public, industry and governments. it may be
possible to divert the majority of plastic waste from landfills to recycling over the
next decades. This product is used for cutting and crushing plastic in small pieces to
make waste management easier. We are making this project model for recycling of
plastic wastage in domestic area, industries etc. in this area the plastic waste is present
in large quantity. But the available machines used to recycle this waste are very
costly. So, our intension behind this project is to process the plastic waste as cheap as
possible by crushing. Benefits of this machine are the reduction of labor work which
results in cost reduction.

Plastic Recycling is an important issue in today’s society and one that has gradually
gained momentum over the years wastes and threats to the environment and human
health have grown. As technology develops, the number of materials that can be
reused or recycled also grows. Given current population trends and the number of
wastes that will be produced, recycling and reuse needs to take a front seat in our
everyday lives. We can primarily focus on the packaging industry and how that relates
to recycling. Since plastics are so prevalent in the packaging/consumer industry they
will have an effect on recycling rates. The increase in plastics may pose serious
problems for waste disposal operations, which are almost all managed by local
governments. As landfill space diminishes and as new landfills are becoming nearly
impossible to site, solid-waste planners must look to other methods of waste
management

Plastic crushing machine is also called plastic shredding or plastic shredder, it is a

solid waste reduction machine environmental crushing equipment, and applied to
shred plastic products and materials, which is beneficial to plastic recycling and

6
recycled plastic pellets. For example: PET bottles, gasoline bottles, plastic barrels,
plastic sheets, etc. Plastic crushing machine is a multifunctional plastic recycling
equipment. Cutter/crusher is a mechanical device used to cut plastic into Undefined
Flakes, we design this project for recycling of plastic, Recycling Reduces the waste
Management Solution. Cutter Machine Includes Crusher Setup with Single Axle Shaft
basic purpose is to Cutting of material Depends of Shear Strength and Impact
Strength. Machines Available for Recycling are costlier and setup is also high, to
overcome this Problems we developed Plastic cutter machines, with this machine
individual start the recycle setup without wise enough skill [1, 2].

.2. Problem Statement

Municipal Solid Waste (MSW) management is gradually becoming a plague that

requires immediate attention for optimum protection of public health and
environment. This is as a result of increasing population growth, high rate of
consumption, urbanization, lack of effective waste management plan etc. [12] In
recent times, studies have shown that apart from the environmental pollution and
contamination of ground water by organic waste, plastic waste such as polyethylene
terephthalate (PET) bottles is one of the waste management problems hampering the
developmental and aesthetical state of our environment as a result of its indiscriminate
disposal.

Polyethylene terephthalate (PET) is a polyester made from terephthalic acid (a di-

carboxylic acid) and ethylene glycol (a di-alcohol) through the process of
polymerization. Since the introduction of PET bottles over 60 years ago,
manufacturers as well as consumers have grown increasing interest in the use of PET
bottles due to a number of reasons [13]. In attempt to prevent sharing of drinking cups
and maintain hygiene, PET bottles became widely acceptable because they are
disposable, cheap, lightweight and made of durable materials which can readily be
molded into different shapes and sizes relevant to a wide range of applications [14].

As a result of the world’s increasing population, there has been a high tendency for
empty PET bottles to increase. Not only this, Bottles and other rigid plastic packaging
made from polyethylene terephthalate (PET) are continuing to grow in demand

7
despite pressure over their environmental impact. A recent Smithers [15] study
reveals. While Covid-19 is the immediate challenge, in which protective devices that
made from plastics like sanitizer packaging, face glass and etc. needs new recycling
technologies and alternative feedstocks will be increasingly important over the five
years to 2025.

Data from the Smithers market report The Future of PET Packaging to 2025 shows
global demand will reach 22.65 million tone’s, with a value of $44.1 billion in 2020.
The impact of Covid-19 is still unclear, and while volume consumption will increase
this year, overall value could shrink by as much as 17% compared to 2019. As it
recovers, future growth in this segment is forecast at a compound annual growth rate
(CAGR) of 3.7% pushing consumption to 27.13 million tone’s in 2025. Bottled water
and carbonated soft drinks (CSDs) are the dominant markets for PET packaging. In
2019, bottled water was the largest end-use market, accounting for 34.6% of global
PET packaging consumption, with CSDs representing 27.1%.

Figure 2.1: Ethiopia's plastic consumption 2007-2020

This statistic depicts the plastic consumption in Ethiopia from 2007 to 2015, and
estimated figures from 2016 to 2020. In 2015, the plastic consumption volume in
Ethiopia reached around 172,000 tons. This figure is expected to increase to some
308,000 tons of plastic by 2020.

This statistic poses the huge quantities of PET bottles currently being marketed and

8
consumed possibly find their way into waste dumpsites, and this creates serious
environmental problems. However, indiscriminate disposal of PET bottles and other
non-biodegradable materials end up clogging drainage systems during raining season,
causing flood and waterlog in residential areas which consequently serve as breeding
ground for vectors such as mosquitoes. [16]

.3. Objective

1.3.1. Main Objective

The general objective of this thesis project is to design, analyze, and simulate plastic
crushing/cutting machine as per specified CAD design.

1.3.2. Specific Objective

 To design all components of the plastic crushing machine

 To design all components/parts model with Solidwork software.
 To optimize the design of cutter/blade with ANSYS Software
 To minimize overall cost
 To design ease maintainability and assembling
 To design ease manufacture for local production
 To design the machine as per aesthetics and ergonomics

.4. Scope of the project

The scope of this thesis project starts from problem identification; exploration of
suggested solutions; describing the conceptual designs of a crusher and choose the
suitable one with its working mechanism according to the selection criteria; then
design, analysis and simulation of each individual parts and components. The crusher
will help in managing and recycling plastic waste. It would also help in reducing the
volume of waste generated and will thus help in effective waste management.

9
 .5. Significance of the project

Majority of plastics recycling machine are imported and costly, hence there is need to
locally develop a recycling machine from locally sourced materials to make their
fabrication cheaper. After Studying various machines, we found out that they were
build up for large scale industries which occupies a lot of space and energy. We are
stiving to develop plastic crusher machine, which can be portable as well as useful for
small scale industries, Recycling Plants, Small Societies, Municipal Dump Grounds
etc. Also, these machines are less costly and not heavy. The overall survey helped us
decide our current design and product. This project is intended to the design, analyze
and simulate the plastic crusher machine with in the plastic recycling process. But the
plastic recycling process project is further going to extrusion, injection, blow molding,
and film molding techniques that produce items such as pipes, bottles bags, sheets etc.
from crushed plastic debris. that is not our concern within the scope, and also
developing the prototype by specified criteria is excluded.

.6. Methodology

Our product development design of plastic crushing machine to achieve of the main
objective and specific objective through the steps and method that flowchart below
used in this process to optimization of the machine.

Method of analysis starts identifying customers requirement in relation with

engineering characteristics. Based on that generate concepts having different
mechanism and select the appropriate one. Then analyze the design details and also
optimization process as shown in the block diagram below.

10
 Block diagram of design methodology of plastic crusher machine

Concept Concept Embodiment

Concept
generatio evaluation design
selection
n

Roll crushing
Product
shaft (material Detail design
definition
optimization)

Consideration of
manufacturing

Product
development cost

Result and
discussion

11
 CHAPTER TWO

2. LITERATURE REVIEW

.1. Historical Development of plastic crusher

machine

The first generation of shredders transmission mechanism is driven by a belt with low
noise, but the belt may be pulled and deformed after long working hours, even the
breaking phenomenon, and the surface of the belt teeth is effortlessly worn and the
machine running may slip.

The second generation of crushers plastic gear rolls, because it is difficult to master
injection and shrinking process accurately of the shredder machine, resulting in the
low accuracy of the gear itself. And running at highspeed, the noise is large. Due to
the brittle plastic parts, poor toughness, it is prone to appear the phenomenon of
broken teeth [2].

The third-generation shredders Metal sprocket: quiet operation, low energy loss,
efficient cutting, and the perfect coordination of the various components of the system
achieve the compelling features.

The fourth generation of shredder machine the drive mechanism of shredder machine
is the metal gear, although the metal gears overcome the above drawbacks, it is
difficult to avoid the impact of the metal gear and friction sound. Due to the mounting
accuracy of the metal bodies, the lubrication conditions of the gear meshing, technical
and maintenance of the lubrication effect and uncontrollable long-term operation,
there will be a lot of noise at high-speed operation.

The fifth generation of shredder machine Diamond snug movement, it takes use of
alloy steel materials, quenching process of metal tool, completely CNC machining
technology, and the workmanship guarantee transmission installation accuracy, so the
wear is reduced to a minimum to ensure the stability of product quality and reduce

12
noise. We can assurance the quality of single shaft shredder with the super full rigid
all-metal gear which is made of steel roller knife, high quality powerful motor [4].

The sixth generation of shredders (modern)Currently, the high-tech multimedia high

series grinder has the high technology content which can be used to broken CD-ROM,
floppy disk, tape, video, etc. and the embedded button panel with a protective film
ensure the function of the way forward, rewind, stop, and full stop.

In the contemporary world, we pay attention to care for the eminence of life, we have
higher requirements for the environmental protection of the product functionality,
performance, security, therefore, the functions, such as carton storage partitions,
motor overheating protection, load automatic shutdown function, storage carton not
closed the automatic power-off are be more and more used in the room.www.3e-
recycling.comAs the subsidiary of Guangzhou Lian guan Machinery Co., Ltd.,
Guangzhou 3E Machinery., Ltd. specialized in developing and producing a series of
environmental protection recycling machines, such as tire recycling machines, cable
recycling machines, circuit board recycling machines, timber recycling machines,
aluminum and plastic packing recycling machines, plastic recycling line, shredder
machine, and so on[17].

.2. Advantages of Recycling Plastics

Plastics should be recycled because of a number of reasons as can be seen below:

1. Provision of a Sustainable Source of Raw Materials: Recycling plastics

provides a sustainable source of raw materials to the manufacturing industry.
Once the plastics are recycled, they are sent to manufacturing industries to be
redesigned and converted into new shapes and used in different appliances.
2. Reduces Environmental Problems: Since plastics are non-biodegradable, they
pose a high risk to the people and the environment as a whole. They can block
sewer lines, drainages and other waterways leading to blockages and
unwanted pileups. When plastics are eliminated through recycling, the
environment looks clean and inhabitable.

13
 3. Reduces Landfill Problems: Recycling plastics minimizes the amount of
plastic being taken to the ever-diminishing landfill sites. Most countries have
designated areas specifically meant for burying plastics. When they are
recycled, these sites will receive little plastic garbage. The remaining areas can
be used for other purposes instead of dumping plastics that do not rot. These
areas can be used for agriculture or for human settlement. It should be
understood that human population is growing each day and land is becoming a
problem. Instead of misusing the land for garbage disposal it can be used for
settlement and other important economic activities.
4. Consumes Less Energy: Recycling of materials including plastics requires less
energy as compared to making the plastic from scratch. This saves energy and
that energy can be diverted to other important things in the economy. It is
therefore important to encourage plastic recycling in the manufacturing
industry as it will save the economy billions of moneys. The process of
manufacturing plastic using natural raw materials is expensive and time
consuming compared to the recycling process.
5. Encourages a Sustainable Lifestyle among People: Individuals who have
ventured into plastic collection and recycling business will experience
improved lifestyles as they will get their daily income from the business. This
will in the long run improve the economy and boost the living standards of the
people. So do not just sit there doing nothing, embrace plastic recycling
activities and improve your economic standards.

In summary, any sort of effort aimed at saving the environment is very important and
matters a lot. Since its inception during the environmental revolution in the late
1960s, plastic recycling is one of the most encouraged solid waste management
programs in the world. Prior to the push to use of plastic containers by manufacturers,
products were packaged in glass, metal and paper. Therefore, in order to keep our
environment clean, reduce landfills, provide a sustainable supply of plastics to
manufacturers, it is important to recycle plastics.

14
 .3. Working principle

The operation of the crushing machine is not complex at all. During the process, the
plastic is crushed and stored in the hopper with the push of a button. Equipped with a
blade, the machine, performs all the work quickly, without disturbing noise, and with
little energy consumption. You can find some plastic crushing machines that have
been manufactured for the recycling of special plastics or that include extra functions.
But the vast majority of them will allow you to dump the plastic, crush and compress
it for easy storage. Keep in mind that plastic is a very versatile material that is used in
large quantities at an industrial level. In the factories, its continuous use makes the
crushing machines one of the indispensable tools for its management and recycling.
This crusher is used to reduce large pieces of plastic crushing without having to do it
manually or by more rudimentary procedures. The industrialization of the process
makes it much faster and more efficient.

15
 figure 2. 1: flow chart of plastic recycling process

Table 2. 1: Cutting machine comparison

Previous version plastic cutters Our version of Portable Plastic cutter

Expensive Relatively cheaper
Requires plenty space Compact in design
Complicated assembly Easy assembly

16
 Large Power required Relatively less power
Stationary Portable
Difficult to replace parts Easy to replace parts
Heavy Comparatively light

Besides these, the machine was also designed with the following Assumptions
constraints considerations:

 Simplicity in design of the machine

 Ease of operation with low noise, portable and compact size
 Easily replaceable parts and ease of inspection
 It Can be manufactured in Ethiopia (foreign currency reduction).

Table 2. 2: mission statement

Product description Plastic shredding machine

Benefit proportion  Cost minimization

 Easy to maintain
 Material optimization

Key business goal  Create employment opportunity

 Safeguard the environment
 Provide clean and safe living condition

Primary market Entrepreneurs that useful plastic type to molding,

city, zone and region waste management
administration, plastic molding manufacturing
factories,

Secondary market Manufacturing of plastic crushing machine,

maintained and replacements of machine workers

Assumption  Electricity assisted

 Plastic waste

17
 .4. Previous work related with plastic cutter

Y. M. Sonkhaskar, et.al [19] Has been explained about design of a Plastic Bottle
Crusher which would help to crush the used Plastic bottles and would thereby help in
waste management and disposal. This project aims to design a portable Plastic Bottle
crusher that could be installed anywhere and would aid crush of used bottles.

Dr M. M. Sadiq, M. R. Khattak, Plastic waste is silent threat to the environment

and their disposal is a serious issue for waste managers. Now a day society does not
have any alternative to plastic products like plastic bags, plastic bottles, and plastic
sheets etc. In spite of all efforts made to limit its use but unfortunately its utility is
increasing day by day. To circumvent this issue many efforts were made in the past to
reuse the plastic waste but no significant results were achieved [20].

Vishal N. Kshirsagar describes about the experimentation of can or plastic bottle

crusher machine and analysis of mechanism used in machine. Hence in this the
knowledge of analysis is necessary, and by analysis of various parts the quality and
life of machine can be increased and improved. Overall, for experimentation this
machine involves processes like design, fabrication, analysis and assembling of
different components etc. From this the knowledge of all the parameters like design,
fabrication and analysis etc. will get increase but most important the knowledge of
analysis, the use of Ansys Workbench Software is increasing day by day to determine
the parameters like stress, strain, deflection etc. for safe design and long durability
[21]

A. S. Dhavale, V. R. Muttagi, (2012) Study of Modeling and Fracture Analysis of

Camshaft, International Journal of Engineering Research and Applications, Vol. 2,
Issue 6. After selection of material & heat treatment processes further aims to perform
mechanical & chemical analysis i.e. composition testing of the two tool steel EN-41,
EN-19, before treatment. After composition testing aims to do heat treatment
processes i.e., Annealing, Normalizing, and Hardening & Tempering to be carried on
such material & after treatment aims to perform harness testing on the treated and

18
untreated work samples.[22]

S. Ranganathan and T. Senthivelan (2010), “Optimizing the process parameters on

tool wear of WC inert when hot turning of AISI 316 Stainless steel,” Asian Research
Publishing Network (ARPN), Vol. 5, No.7, pp. 24-35. In this work, the EN 36 Steel
specimens heated with gas flame were machined on a lathe under different cutting
conditions of Surface temperatures, Cutting speeds and Feed rates. Cutting force, feed
force and surface roughness were studied under the influence of machining parameter
at 200 °C, 300 °C, 400 °C, 500 °C and 600 °C at constant depth of cut 0.8 mm. The
optimum result was achieved in the experimental study by employing Design of
experiments with Taguchi. In present study, Analysis found that varying parameters
are affected in different way for different response. The ANOVA analysis was used to
obtain optimum cutting parameters.[23]

N. M. Kamdar, Prof. V. K. Patel (2012), “Experimental investigation of machining

parameters of EN36 steel using tungsten carbide cutting tool during hot machining”,
International Journal of Engineering Research and Application, Vol.2 (3), pp.1833-
1838. This survey helps to find out the place of the work to be carried out i.e.,
availability of setup, techniques used for such, estimated time, various cutting
parameters, surface roughness& cost requires for such study carried out for such
industrial survey to be carried out we designed a Survey questioner and selects
various places who offers heat treatment services Ludhiana based. After literature
review and industrial survey indicate for optimal cutting parameter, minimum surface
roughness (Ra) and maximum material removal rate were obtained and developed
model can be used to increase the machine utilization at low production cost in
manufacturing environment.[24]

Joseph Y. Ko in 2000 presented a machine with automatic feeding mechanism

capable of cutting 20 sheets with approx. 9 inches width. It had a three-way switch
i.e. On, Off and Auto. The blades were knife rollers which cut paper strips, but can be
occasionally configured to have confetti-cuts of paper. Feeding mechanism contained
a pair of rollers to direct the paper. The rollers and the knife blades were driven by a

19
single AC Motor and a belt drive.[25]

Frank Chang in 2000 presented the blade assembly for paper cutter is in a
juxtaposed manner. Conventional assembly consists of long and short partition rings.
The disadvantage was that even if one part malfunctioned, the whole assembly gets
loosened. Instead of having partition rings it had long and short plates casted with the
blade ring. The blades were arranged on the rotary shaft to form a bladed shaft such
that long and short projecting about the long and short projecting plates of adjacent
blades. This arrangement eliminated use of partition rings, reducing cost and
enhancing assembly efficiency.[26]

Gu-Ming Zeng in 2006 presented the blades of the paper cutter that had serrated
cutting edges which were formed by bending. This could be done by two methods.
The 1st method had a blade body and serrated edge integrally formed and punched
from the same base material. Cost of production there was high and even high-level
material was required. The 2nd method had serrated cutting edges specially thickened
to reduce material consumption. They were also complex to manufacture. Three types
of blades could be designed according to him.

a. 4 serrated edges evenly spaced with one annular protrusion.

b. 2 serrated edges with corrugations on outer periphery.

c. 2 serrated edges with 3 annular protrusions evenly spaced.[27]

Ming- Hui Ho. in 2003 presented the paper cutter which had two rotary cutters each
with multiple blades. Each blade had a first cutting blade with multiple first cutting
edges and a second cutting blade with multiple cutting edges. Both the first and the
second cutting blades were distributed in a non-equiangular manner and each of the
first cutting edges was offset to each one of the second cutting edges, so that there
was only one cutting edge that engaged with the paper to be crushed. When the
amount of crushed paper increased, the paper cutter did not function normally
because multiple cutting edges simultaneously engaged with the paper to be crushed
paper stuck in the cutter. This problem was sorted out by using rotary cutter with

20
multiple blades with numbers cutting edges. With the arrangement described here, the
noise of the cutting was also greatly reduced.[28]

W. Strohmeyer in 1995 presented a blade and a stripper assembly for a paper cutter.
Between the blades of each shaft in the cutter zone, stripper bars or fingers were
provided to prevent the cut material get collected around the blade shaft. Here the
stripper block had the row of stripper fingers received in the interstices between the
blades. Requisite stability was attained since the fingers were engaged with the
support ribs of the opposite housing. Stripper block was an injection molding part,
thus was simple construction and easy to fabricate and also had low cost.[29]

21
 CHAPTER- THREE

3. CONCEPTUAL DESIGN

.1. List of Customer requirements

Identifying customer needs is an integral part of the concept development phase of the
product development process. The resulting customer needs are used to guide the
team in establishing product specifications, generating product concepts, and selecting
a product concept for further development.

Figure 3. 1: flow chart of customer requirements

Gather raw data from customers defined by all the customers of the product that is to
be designed. As needs are essentially a wish- list provided by the customers, we have
to ultimately translate these needs into a set of specifications that identify how the
product will function from a technical standpoint. In order to ensure that these needs

22
are fully addressed as specifications, a middle step is required to aid an accurate
transformation. This stage is called the ‘Requirements’ stage and involves our
interpreting and prioritizing these needs into product requirements, which essentially
identify the objectives of the product.

Interpret the raw data in terms of customer needs: In order to prioritize

requirements, we assign an importance rating for each requirement from 1 to 10,
where 10 is the most important and 1 is the least important. Another distinction that is
usually made is whether a particular requirement for the product is essential or not. If
it is considered essential, then it is classified as a ‘Demand’ and denoted with a letter
‘D’. A ‘Demand’ is always given the top rating value of ‘10’. Other non-essential
requirements are considered to be ‘Wishes’ and are denoted with a letter ‘W’. The
ratings for these ‘Wishes’ vary from 1 to 10 as described below.

Table 3. 1: list of customers requirement’s

list of customers Wish list of customers Wish

requirement’s and requirement’s and
Demand Demand
Easy to use W Easy to Operatable W
Easy to clean D Appearance pleasing to eye D
(stylish and fashionable)
Low vibration D Easy to stop D
High material strength D Enough force to crush D
plastic

23
 Long running capability W Minimum cost to D
manufacture
Compact size W Parts easily accessible D
Portable D Low friction between D
bearing and their
components
Easy to access to clear knives D Internal parts totally W
cutter enclosed
Easy disassemble D Can cutter with high W
performance
Paintable surface D Cheaper D
Low noise D Light weight D
list of customers Wish list of customers Wish
requirement’s and requirement’s and
Demand Demand
Low operation cost D Little heat produced D
Low maintenance cost D Continuous W
Low cutter force W No/little service required D
Many plastics crushed per D Low cost of replacement D
minute

.2. Organizing customer requirements

Organizing the needs into a hierarch: The objectives tree method offers a clear and
useful format for such a statement of objectives. It shows the objectives and the
general means for achieving them which are under consideration. It shows in a
diagrammatic form the ways in which different objectives are related to each other,
and the hierarchical pattern of objectives and sub-objectives. The procedure for
arriving at an objectives tree helps to clarify the objectives and to reach agreement
between clients, managers and members of the design team.

24
Figure 3. 2: weight objective method diagram

25
Establish the relative importance of the needs: The objectives and sub-objectives at
different levels were weighted in the manner described in the procedure (see Figure
above). The design team then went on to devise measurable or assessable parameters
for all of the objectives, as indicated in the comparison chart.

.3. Establishing function structure

The overall function of a product is the relationship between its inputs and output.
The function of the product can be further broken down to subfunctions that identify
purposive actions that my product is meant to perform. Whereas requirements, as set
by the customer, are ‘wish-lists’ that describe what the product should do, functions
are solution-neutral engineering actions that the product will perform [31].

Function decomposition and structure: Functions should be broken down as finely

as possible. This process is known as functional decomposition and is represented as
the functional structure of the product. A functional structure consists of the following:

• A boundary box (with inputs and outputs)

• An overall function

• Function tree

• Known flow of materials, energy, and information

A boundary box (with inputs and outputs): The simplest form of a functional
structure of a product is represented as the overall function diagram

overall function: shows a transparent version of the box model depicting the
subfunctions of the product. The subfunctions here are known as the function tree of
the product and essentially identify the actions and sequences needed to perform the
product’s main (overall) function.

Figure 3. 3: block diagram of plastic crusher

26
 Function tree: Many of the subfunctions can be divided into sub-
subfunctions. The division depends on the type of design system being considered.

Figure 3. 4: function tree

.4. Product specifications

The objective tree and the structural functions do not set specific limits on the
different functions and objectives. The objective tree or function structures are
statements of what a design must achieve or do, but they are not normally set-in terms
of precise limits, which is what a performance specification does.

Target specifications represent the hopes and aspirations of the team, but they are
established before the team knows the constraints the product technology will place
on what can be achieved. The team’s efforts may fail to meet some of these
specifications and may exceed others, depending on the details of the product concept
the team eventually selects. the objective tree and the structural functions do not set
specific limits on the different functions and objectives. The objective tree or function
structures are statements of what a design must achieve or do, but they are not
normally set-in terms of precise limits, which is what a performance specification
does. The process of establishing the target specifications entails four steps:

 Prepare the list of metrics

 Collect competitive benchmarking information.
 Set ideal and marginally acceptable target values.

27
  Reflect on the results and the process

Performance-specification method: the need statement for the plastic solid crusher,
the specifications that must be met are:

 The design of the crushing mechanism is not to exceed in the total size.
 The can crusher must have a continuous feed mechanism.
 The can must be crushed to 1/5 of its original volume.
 The device must operate safely..

Table 3. 2: Performance-specification method

No metric Imp. Marginal - value

.

1 dimensions 120 *40*60 cm

2 Plastic crushed 1/5 original volume

3 Weight <150 kg

4 Sales price < 16,000 birr

5 No. of parts < 100

6 People able to use >5 years

7 Probability of injury < 0.1%

8 Manufacturing cost < 4000 birr

9 Steps to operate 1

10 Maintenance cost < 1000 /annual

11 Efficiency rating > 95%

12 Internal parts enclosed 100 %

13 Loader capacity of plastic 60

14 Storage of crushed plastic bottles >30 plastic bottles

28
15 Crush plastic bottles >= 15 plastic bottles/min

>= 1.2*102 m3/min

>= 0.57 Kg/min

16 Noise out put >= 30 dB

17 starts < 10 sec

18 Runs >2 hrs. at time

19 Stops < 5 sec

20 Vibration magnitude < 5 mm

21 Vibrations < 4 sec and

<= 250 N (with stand)

22 Maintenance < 4hrs./years

23 No. of colors 6

24 Life span >4000hrs.

29
 .5. Quality Function Deployment method (QFD)

Quality Function Deployment method (QFD): known as house of quality, recognizes

that the person who buys (or who most influences the buying decision for) a product
is the most important person in determining the commercial: success of product. If
customers do not buy it, then the product, however well-designed it may be, will be a
commercial failure. Therefore, the voice of the customer has priority in determining
the product's attributes. This means taking care to identify who the customers are, to
listen carefully to what they say, and to determine the product's engineering
characteristics in the light of this. As it is presented here, QFD is essentially
concerned with the translation of customer requirements into engineering
characteristics [32].

customer perceptions of their product and of competing products, and how the
engineering characteristics of the product relate to customer requirements. In this step
of the procedure, we determine the targets that can be set for the measurable
parameters of the engineering characteristics in order to satisfy customer requirements
or to improve the product over its competitors.

a b c

Figure 3. 56: (a) competitive 1, (b)competitive 2, (c) competitive 3

competitive situation it is important to know what the competitors achieve on the
characteristics of their product, so detailed investigation of competitor products
necessary. We can set targets for themselves which would be better than the
competition. it necessary to conduct trials with customers in order to determine what
would be acceptable target figures to set. This is similar to determining values in a
performance specification.

30
31
32
 .6. Concept Generation

A product concept is an approximate description of the technology, working

principles, and form of the product. The degree to which a product satisfies customers
and can be successfully commercialized depends to a large measure on the quality of
the underlying concept. The concept generation process begins with a set of customer
needs and target specifications and results in a set of product concepts from which the
team will make a final selection.

Figure 3. 7: concept generation

3.6.1. Developing working structures

Once the functions at various levels are known, it is important to find the principles at
work for each of the functions and subfunctions. A working principle must be based
on the physical effect needed to achieve the given function based on the flow of
materials, energy, and information within each function. Each function may be
achieved in a number of ways. One important tool that can be used effectively is a

33
design catalog or morphological chart

Table 3. 3: morphological chart

A B C d

1 Energy IC engine Electrical Fuel - cell Motor gear

conversion motor box
reduction

Rotary Ac induction Battery Helical type

reciprocating Dc motor Worm type

2 Energy Gears Belts Chain couple

transmissio
n

Spur Flat roller Rigid

Helical Wedge leaf Flexible

Bevel Round conveyor universal

Worm synchronous salient

3 Energy flywheel Spring reservoir Solid mass

storage
Helical

Leaf

Rubber

4 Friction Rolling element Sliding brush Wheels and

reduction element roller

Bearing Bearing Ball rolling

Cylindrical roller Hydro Taper rolling

dynamic

Taper roller Hydro static Cylindrical

34
 Deep groove Slide bearing

Angular contact

5 locating Thread fasteners Pin Rivet keys

Bolts Cylindrical Flat

Nuts and lock Taper Adhesives

Grub screw Spring

Washer

6 pulleys Solid

7 Filters

8 housing Frame casings Enclosures

9 Cutter

10 hopper Trapezoidal Cone Rectangular

shape

11 stopping Beaker circuit Ratchet Mechanical clutch

brake

12 operator Standing Remote Seated at

control front

3.6.2. sketch assembly of alternatives

Using the different functional alternatives presented in the morphological chart, our
engineering sense, and a specification table, choose a set of four alternatives. Having
chosen the set of alternatives, we need to sketch them as devices, not as a set of
functions. The conceptual sketches are not detailed. The sketches serve as a first
presentation of the prospective design. Also, sketching reveals information about
details that may be needed later, which will also help in evaluating the concepts.
Assembly of the functional mechanisms will help the visual conceptualization of the
alternatives and will provide a presentation tool to the customer.

Concept alternative 1: flywheel type – single roll spiral crusher

35
 Figure 3. 7: concept alternative 1

Concept alternative 2: belt type – welded cutter roll crusher

36
 Figure 3.8: belt type - welded cutter roll crusher

Concept alternative 3: bevel gear type – pyramid cutter conical crusher

Figure 3. 9: concept alternative 3

Concept alternative 4: worm type – teeth cutter roll crusher

37
 Figure 3. 80: concept alternative 4

.7. Concept selection/evaluation

Concept selection is the process of evaluating concepts with respect to customer needs
and other criteria, comparing the relative strengths and weaknesses of the concepts,
and selecting one or more concepts for further investigation or development.

3.7.1. Pugh’s evaluation matrix

Pugh’s evaluation matrix is used when increased resolution will better differentiate
among competing concepts. In this stage, the team weighs the relative importance of
the selection criteria and focuses on more refined comparisons with respect to each
criterion. The concept scores are determined by the weighted sum of the ratings. In
describing the concept scoring process, we focus on the differences relative to concept
screening. As a result, for sake of our design product; belt type power transmission
(concept 2) with welded roller crusher is selected as the best and efficient way of
plastic crushing machine; to easily manufacture based on the listed criteria compared
to other alternative solutions.

38
 CHAPTER FOUR

4. EMBODIMENT DESIGN

This section discusses presentation of the concept(s) that pass the evaluation
criteria. The idea of presenting information through drawings was introduced when
different concepts were generated from the morphological chart. The sketches that
present the concepts are not detailed: They simply provide enough information to
demonstrate the combination of the different function mechanisms that produce the
concept.

.1. Product definition

1. shaft: a component of circular cross-section that rotates and transmits power

from a driving device, such as a motor or engine, through a machine.

Figure 4. 8: shaft

2. Pulley (driven and driving): pulley supported by a frame or shell that does not
transfer power to a shaft, but is used to guide the cable or exert a force, the
supporting shell is called a block, and the pulley may be called a sheave.

39
 Figure 4. 9: pulley

3. V-belt: The purpose of a belt or chain drive is to transmit power from one
rotating shaft to another. The speed ratio between the driving and driven shaft is
dependent on the ratio of the pulley.

4. Spur Gear(a): spur gear is the type of power transmission element that transmits
the power flow through the shaft to the crushing blade by engaging individual
gears.

Figure 4. 10: (a) spur gear, (b) crushing blade, (c) hopper

5. Knives cutter (crushing blade) (b)- one of this product mechanical component
used to crush the plastic that comes through the hopper with the help of feeder
gate.

6. Feeder(hopper) (c) - apiece of sheet metal folded to hold the plastic bottles

7. Ejector-to take away the plastic debris from plastic crusher housing

8. Housing- a housing is an exterior case or enclosure used to protect an interior

mechanism, including integrated fittings or brackets to keep internal components
in place. The housing prevents the interior mechanism from being fouled by

40
 outside debris or to contain the internal components. Housing may be the body of
the device, vital to its function.

9. Bolt- Bolts are for the assembly of two components, with the aid of a nut.

Figure 4. 11: bolt and nut

10. Frame: a metal structure to support the plastic cutter or crushing machine

figure 4. 12: frame

11. Sieve: Filtration is any of various mechanical, physical operations that separate
fine and coarse plastic scattered by adding a medium through which only the fine
plastic debris can pass.

figure 4. 13: sieve/filter

41
12. Key(a): a key is a machine element used to connect a rotating machine element
to a shaft. The key prevents relative rotation between the two parts and may
enable torque transmission. For a key to function, the shaft and rotating machine
element must have a keyway and a key seat, which is a slot and pocket in which
the key fits. The whole system is called a keyed joint. A keyed joint may allow
relative axial movement between the parts.

figure 4. 14: (a) key, (b) roller bearing

13. Bearing(b): a mechanical component used for easy and desirable motion of
shaft.

14. Electrical motor- a source of power that transmit motion to power transmission
of belt. The purpose of a motor, regardless of the application, is to change
electrical power to mechanical power in order to provide rotational movement.

.2. Assemble method

Design for assembly (DFA) is the study of the ease of assembling various parts and
components into a final product. A lower number of parts and an ease of assembly
contribute to reducing the overall cost of the product. With DFA, every part has to be
checked. It must be determined if it is a necessary part, if it would be better integrated
into other parts, or if it should be replaced by a similar function part that is simpler
and costs less. Integrating both design for manufacturing and design for assembly
helps contribute to the competitive success of any given product by matching that
product’s demands to its manufacturability and assembly capabilities.

42
 .3. Manufacturing method

Manufacturing processes can be classified under the headings shown in below.

 Primary shaping creates shapes. The first row lists six classes of primary
forming processes: casting, molding, deformation, powder methods, methods
for forming composites, and special methods such as rapid prototyping.
 Secondary processes modify shapes or properties; here they are shown as
“machining,” which adds features to an already shaped body, and “heat
treatment,” which enhances surface or bulk properties. Below these come
joining an, surface treatment or finishing.
1. Casting processes. In sand casting, liquid metal is poured into a split sand mold. In
die casting, liquid is forced under pressure into a metal mold. In investment
casting, a wax pattern is embedded in a refractory, melted out, and the cavity
filled with metal. In pressure casting, a die is filled from below, giving control of
atmosphere and of the flow of metal into the die.

2. Molding processes. In injection molding, a granular polymer (or filled polymer) is

heated, compressed, and sheared by a screw feeder, forcing it into the mold cavity.
In blow molding, a tubular blank of hot polymer or glass is expanded by gas
pressure against the inner wall of a split die. In polymer extrusion, shaped sections
are formed by extrusion through a shaped die. In thermo-forming, a sheet of
thermoplastic is heated and deformed into a female die by vacuum or gas pressure.
3. Deformation processes. In forging, a slug of metal is shaped between two dies
held in the jaws of a press. In rolling, a billet or bar is reduced in section by
compressive deformation between the rolls. In extrusion, metal is forced to flow
through a die aperture to give a continuous prismatic shape. All three processes
can be hot (T > 0.85 Tm ), warm (0.55 Tm < T < 0.85 Tm ), or cold (T < 0.35
Tm ). In spinning, a spinning disc of ductile metal is shaped over a wooden
pattern by repeated sweeps of the smooth, rounded tool.
4. Machining operations. In turning and milling, the sharp, hardened tip of a tool
cuts a chip from the work piece surface. In drawing, blanking, and stretching,
sheet is shaped and cut to give flat and dished shapes. In electro-discharge

43
 machining, electric discharge between a graphite electrode and the work piece,
submerged in a dielectric such as paraffin, erodes the work piece to the desired
shape. In water-jet cutting, an abrasive entrained in a high-speed water jet erodes
the material in its path.
5. Joining operations. In adhesive bonding, a film of adhesive is applied to one
surface, which is then pressed onto the mating one. Fastening is achieved by
bolting; riveting; stapling; pushthrough snap fastener; push-on snap fastener; or
rod-to-sheet snap fastener. In metal fusion welding, metal is melted, and more is
added from a filler rod to give a bond or coating. In thermoplastic polymer
welding, heat is applied to the polymer components, which are simultaneously
pressed together to form a bond.
6. Finishing processes to protect and enhance properties. In mechanical polishing,
the roughness of a surface is reduced and its precision increase, by material
removal using finely ground abrasives. In electroplating, metal is plated onto a
conducting work piece by electro-deposition in a plating bath. In heat treatment, a
surface layer of the work piece is hardened and made more corrosion resistant by
the inward diffusion of carbon, nitrogen, aluminum from a powder bed or molten
bath.

44
 .4. Working principle

Types of plastic solid waste are sorted as per the size of shredder machine. Once The
power supply unit is turned on, the machine blades are rotated. The plastic wastes are
put into the hopper of the shredder machine. These are shredded by the shredding
machine blades in a various size based on the size of blade configurations. The size of
output wastes can be also determined and modified by the adjustment of a machine
attachment called filters. Once the wastes are shredded into strips forms, they are
cleaned, chemicals and additives are added. These waste shredded plastics are reused
to form different products by various operations (I.e., moldings, compression process)

.5. Maintenance/Design for Maintainability

Design for Maintainability Basic Principles Maintainability is the degree to which a

product allows safe, quick and easy replacement of its component parts. It is
embodied in the design of the product. A lack of maintainability will be evident as
high product maintenance costs, long out of service times, and possible injuries to
maintenance engineers. One measure of maintainability is Time to Repair (TTR, also
known as ‘turn-around time’). In large pieces of equipment, maintenance times might
be listed for different tasks on individual parts of the equipment. Two kinds of
maintenance activity can be identified for any product:

1. Preventative maintenance, the replacement of parts that are still working but are
expected to fail soon. It is also undertaken where degradation of a component
endangers components elsewhere in the product. For example, the crushing blade
may cause serious shaft and spacer damage by etching the upper part of them, or
allowing high frictional heat production. each of these different types of
maintenance.

 Time Based Maintenance (TBM)

 Failure Finding Maintenance (FFM)
 Risk Based Maintenance (RBM)
 Condition Based Maintenance (CBM)

45
  Predictive Maintenance (PDM)
2. Remedial maintenance (repair), for example fitting a new electric motor where
the existing motor has burned out. Remedial maintenance is performed after the
product has failed.

 Deferred Corrective Maintenance

 Emergency Maintenance (EM)

46
 CHAPTER FIVE

5. DESIGN ANALYSIS

.1. Electrical Motor Selection

The motor selection process begins with evaluating the application and ensuring the
motor chosen will properly match the needs of the application. Ambient temperature
is also an important factor to take into consideration when choosing a motor.
Designers should pay attention to maximum allowable current early in the selection
process, as it is a consideration that oftentimes goes unnoticed. If the requirements of
the project subject the motor to elements such as dust or water contamination, a
designer should consider a motor constructed for environmentally sensitive
applications.

The characteristics of these single-phase motor are determined in accordance with the
service condition under which they are required to operate.in this respect distinction is
made between the following three classes of motors continuously operating motors,
motors for frequent starting and reverse current braking, motors for driving machine
tools with large inertia which small suitable slip.

In general, the following refer to single phase squirrel cage induction motors, thus the
selection of motor is based on determination of the total power required for the
system. For our case power consumed by the shaft rotating the crushing blade is
considered. These design needs 137 Kilowatts motor can be used to operate this
machine having the same specification.

47
Table 5. 1: motor selection evaluation

48
49
Type of motor universal DC permanent AC induction motor Brushless motor

Motor standard Wt Wv Wv Wv Wv

Voltage 20 AC, DC 0 DC -1 AC +1 AC, DC 0

Speed 10 8000 – 20000t -1 350 – 6000 0 1200 – 3400 +1 2300 - 3800 +1

Horse power 10 Very high 0 Medium +1 Low – medium 0 High 0

Life span 10 Low -1 Medium 0 Very high +1 Very high +1

Maintenance 8 High -1 Medium 0 Very high -1 Very high -1

Noise 8 Noisy -1 Medium 0 Quiet +1 Very quiet +1

Speed-regulation 10 Poor -1 Fair 0 Good +1 Excellent +1

Starting torque 9 High +1 Very high +1 Low – medium 0 Very high +1

Cost 15 Low +1 low +1 High -1 High - cost -1

Total 100 Σ w v =+14 Σ w v =+14 Σ w v =+35 Σ w v =+24

Rank 4th 3rd 1st 2nd

50
continue NO NO YES NO

51
 .2. Design of Belts and pulleys

Transmission of power from a source, such as an engine or motor, through a machine

to an output actuation is one of the most common machines tasks.an efficient means
of transmitting power is through rotary motion of shaft that is supported by bearing.
Gears, belt, pulley or chain sprockets may be incorporated to provide for torque and
speed changes between shafts. Most shafts are cylindrical (solid or hallow), and
include stepped diameter with shoulder to accommodate the positioning and support
of bearings, gears, etc.

Type of belt: There are many types of belt used now days, yet the following are
important from these design subject point of view.

Flat belt: - is mostly used in factories and workshops, where a moderate amount of
power is to be transmitted from one pulley to another when the two pulleys are not
more than 8 meters a part.

Circular belt or rope: -the circular belt is mostly used in the factories and workshops,
where a great amount of power is transmitted, from one pulley to another, when the
two pulleys are more than 8 meters apart.

V-belt: - this belt is mostly used in factories and workshops, where a great amount of
power is to be transmitted, from one pulley to another when the two pulleys are very
near to each other.

Advantage of V-belt: The V-belt drive gives compactness due to the small distance
between centers of pulley. Since the V-belt are made endless and there is no joint
trouble, therefore the drive smooth; It provides longer life,3 to 5 years; it can be easily
installed and removed; The operation of the belt and pulley is quiet; The belt have the
ability to cushion the shock when machines are stored; The high velocity ratio
(maximum 10) may be obtained; The V-belt may be operated in either direction with
tight side of the belt at the top or bottom; and The center line may be horizontal,
vertical or inclined.

52
 5.2.1. Design of V – belt 1

Geometry analysis:

Figure 5. 1: geometry analysis of belt drive

Input data

Operating conditions Driven machine

Drive machine
Daily operation: ~ 18 hrs
Crushing plastic solid
3 – phase AC No. of starts: one per day waste of PET, PP
induction At room temperature
P = 132 KW
motor
No exposure to oil, water & dust

Drive center distance between N2 = 200 ± 15 rpm

P = 132 Kw
1000 and 1200 mm
Start-up: under load
N1 = 1485 rpm Variable pulley dia.:

Load factor C2:

The service factor C2: takes account of the daily operating time and types of driver
and driven machine. It means adverse operating conditions (aggressive dust,
particularly high ambient temperature or effects of various substances) have not been
taken into account.

 The service factors are approximate values: therefore load factor(C2) form
appendics II table taken, C2 = 1.3

53
Design power: pB =( P∗C2 ) ¿ ( 132 Kw∗1.3 ) ¿ ( 171.6 Kw ) -----equ 5.1

Selection of belt profile: from optimum belt SK high performace wedge belts
appendixes IV:select SPB belt profile.

Speed – ratio:

ⅈ= ( ) (
n1
n2
=
1485 rpm
200 rpm )
= 7.425

datum diameter of the grooved pulley: dd1 selected from manufacturers standard
product table appendexs VII, dd1 = 180 mm. we can calculate the d d2 (datum diameter
of grooved pulley) from speed ratio(i).

ⅆd =( ⅆ d ∗ⅈ ) = ( 180 mm∗7.425 ) = 1336.5 mm

2 1

We don’t not manufacture wedge belt with this diameter, it means difficult to
manufacture and to assemble, too. So, we can divide the speed ratio in to two of
different wedge belts. Speed -ratio of first i1 =2.74 and speed ratio of second i2 = 2.74,
then its overall speed- reduction will be given as:

( i 1∗i2 ) = ( 2.74∗2.74 ) = 7.5

So, ⅆd =( ⅆ d ∗ⅈ ) = 180 mm * 2.74 ≈ 493.2 mm

2 1

Note that:select the datum diameter from appendixes VII, dd1 = 500 mm

54

Figure 5. 2: speed reduction in two pulley configurations

Verification of driven unit speed:

( )( )
ⅆd 500 mm
iv = = 2
= 2.77
1
ⅆd 180 mm
1

n2 = v
( ) (
n1
iv
1
=
1485 rpm
2.77
= 536 rpm )
n3 = v
( )(
n2 v
iv
=
2
536 rpm
2.77 )
=193.5 rpm…required: 200±15 rpm (it satisfy the requirement)

Drive center distance (preliminary choice):

Recommended: CD > 0.7*(dd1 + dd2) and CD < 2*(dd1 + dd2)

CD > 0.7*(500 mm + 10mm) and CD < 2*(500mm + 180mm)

CD > 476 mm and CD < 1360,

therefore, we selected CD = 600mm.

Datum length of the V-belt:

CD∗sin ( ϕ ¿ π αΠ
Actual, Lⅆ th =2 + ( ⅆ d +ⅆ d 2 ) + 0( d
ⅆ −ⅆ d )----equ 5.2
2 2 1
180
2 1

z
( ⅆ d −ⅆ d 1)
l ⅆ ≈ 2 CD +1⋅ 57 ( ⅆ d 1+d d ) +
2

th 2
4 CD

( 500−1800 )2
= (2∗600 mm)+1 ⋅57 ( 500 mm+180 mm ) +
4∗600 mm

( 320 )2
≈ 1200mm + 1067.6 mm + =1200mm + 1067.6mm + 42.667 mm ≈
2400 mm
2310.26mm we select the next standard length from, appendixes IV, l ⅆ = 2360mm st

Centre distance: Calculated from l ⅆ and l ⅆ : if l ⅆ <l ⅆ ,

th st th st

55
 CD nom ≈ CD + ( Ld −L ⅆ
5t

2
th

)
if l ⅆ >l ⅆ , CD nom ≈ CD +
th st
( −Ld −L ⅆ 5t

2
th

) , our design < 2360 = l ⅆ st

√[ ]
2
π π
2( d
lds t− ⅆ + ⅆd ) 2
Actual: CDnom≈ l ⅆ - ( ⅆd + ⅆ d 2) +
2
1 2
( ⅆ d 2−ⅆ d ) ---eqn 5.3
−
st 1 1

4 8

CDnom ≈ CD + ( Ld −L ⅆ
5t

2
th

) = 600 mm+ ( 2360mm−2310.26

2 )
= 600mm + 24.87mm = 624.87mm ≈ 625mm

Minimum allowance(x/y) for adjusting center distance,

( xy ) from table; appendixes V: ( xy ≥≥ 3520 mm

mm )

Speed and flex rate of belt: v= ( ⅆd

2
1

)
∗w 1 … w 1=2 π n1

v= ( ⅆd
2
1

)
∗2 π n1 =¿ π n1 ¿

= ¿*180m *1485 rpm) *1m / 60,000 sec)

= 13.99m/sec ≈ 14 m/sec

f b= ( 2∗1000∗v
l dst
) = … (f b max , for SPB wedge belt ≈ 100/sec)

f b= ( 2∗1000∗14 m/ssec
2360 mm ) = 11.86 sec -1

B0 approximate: from appendixes I 149.50:

56
Arc of contact correction factor(C1): The factor C1, corrects the power rating (PN),
when the arc of contact is smaller than 1800, as the PN value is calculated on the arc of
contact, B 0 = 1800 on the smaller pulley.

From table: we can linearly interpolated:

(d ¿ ¿ d 2 +d ⅆ ) B C1
1
¿ 0
CDnom
0.50 150 0 0.9
8
0.512 B C1
0.55 147 0 0.9
8

( 0.512−0.5
0.55−0.5 )=(
B−150
147−150 ) (
0.012
0.05 ) =(
−3 )
B−150
 ( B−150) = (- 3 * 0.24) = -

0.72, then, ( B=−0.72+ 150)= 149.28 0, therefore, linearly interpolated (B =149.28 0

and C1 = 0.98)

Length factor(C3): Length factor, C3 takes into account the flex rate of the belt based
on the reference length for the particular belt profile.

C3, from table appendixes III = 0.93, this results in the following relationships:

Belt length < reference length … C3 < 1.0 PN, for  ⅆd = 180m
1

Belt length = reference length … C3 = 1.0 i = 2.77

Belt length > reference length … C3 > 1.0 n1 = 1485 rpm

Extract from table, in order to linearly interpolate:

Datum Additional
diameter of small power [KW] per belt
rpm pulley ( ⅆd )1
for speed ratio

i > 1.57

57
 (180mm)
1400 10.16 1.15
1485 PN1 PA
1500 10.71 1.24

( 1485−1400
1500−1400 )=(
P N 1−10.16
10.71−10.16 ) =(
1.24−1.15 )
P A−1.15
… linearly interpolated for as much

as to accurate our design of wedge belt.

( 100
85
)=( P N 1−10.16
0.55 ) =(
0.09 )
P A−1.15

P N 1=( 0.55∗0.85 )−10.16 and P A=( 0.09∗0.85 ) −1.15

P N 1 = (0.4675 + 10.16) and P A = (0.0765 + 1.15)

P N 1 = 10.6275 and P A = 1.2265 Kw

Nominal power per belt: P N = P N 1 + P A = (10.6275 + 1.2265) = 11.854Kw

Number of belts: z= ( p∗c 2

) (
p N ∗c 1∗c 3
=
132 Kw∗1.3
11.854 Kw∗0.98∗0.93
=
171.6 Kw
) (
10.8037 Kw
= 4.91 )
(Suggested:  5 high performance wedge belts SPB)

Profile, SPB: Minimum static tension per belt (multiply by factor 1.3 at initial installation)

500∗( 2.04−C 1 )∗p B 2

T= + k∗v ------- eqn 5.4
C 1∗z∗ν

500∗( 2.04−0.98 )∗171.6 Kw

= + 0.19∗(14 m/sec ⁡)2 ≈ 1363 N
0.98∗5∗14 m/ sec

At initial installation: T =(1363 N∗1.3)=¿ 1772 N

Minimum static shaft load:

58
 Sq =2T∗sin ( ) B
2
∗z

= 2∗1772 N∗sin ( 149.28

2 )
∗5 = 17720 * sin ¿

= 17087.05 N, at initial installation multiply by factor 1.3,

therefore; Sq =¿(17087.05N * 1.3) = 22213.12 N or 22.2 Kw

Belt deflection: Eq = ( E∗L

100 )
… E = 1.3 , from diagram appendices IX

L=CDnom∗sin ( B2 ) = 625 mm∗sin ( 149.28

2 )
= 625mm *sin(74.64 ) = 602.67mm

So, Eq = ( 1.3∗602.67
100
mm
) ≈ 7.83 mm
Table 5. 2 belt characteristics

Belt notation Numerical value Units

characteristics
Type of driver unit - Crushing -
machine(7.5Kw)
Calculation power PB 171.2 Kw
Drive power P 132 Kw
Torque at driver pulley M N-m

Driver speed N1 1485 rpm

Effective driven speed N2 536 rpm
Datum diameter pulley 1 dd 1
180 mm
Datum diameter pulley 2 dd 2
500 mm
Datum length Ld 2360 mm
Actual centers CD 625 mm
Actual drive ratio i 2.77 -
Adjustment required (for y ≥20 mm
belt installation
Adjustment required for x ≥35 mm
belt tensioning

59
Actual load factor C2 1.3 -
Belt speed V 14 m/s
Flex rate fB 11.86 Sec-1
Nominal power per belt PN 11.854 Kw
Arc of contact factor C1 0.98 -
Pulley face width span b2 mm
length
Calculated number of Z 2 -
belts
Weight of drive W 0.195 Kg/m
Static shaft load at initial Sait 22.2 N
installation
Static shaft load at Sast 17.05 N
retention
Dynamic shaft load Sadym N
Belt length factor C3 0.93 -
Arc of contact on small β 149.28 0

pulley

60
 5.2.2. Design of V – belt 2

Force analysis of wedge belt for pully-3 and pully-4: In order to component
standardization of use of the same wedge belt power transmission in two speed
reduction to allow the firm manufacture the chunk of wedge belt in higher volumes.
This in turn may lead to lower costs and increase quality. So, the overall geometry
dimension is the same with the first wedge belt that design in previous one. Now we
can calculate and analysis the force analysis as well as the belt deflection.

Nominal power per belt: PN for: dd1= 180mm, i = 2, n1 = 536mm

rpm Datum diameter Additional power kw per

of small pully(dd3) belt for speed ratio i >1.57
500 4.32 0.41
536 PN2 PA2
600 5.06 0.49

536−500 PN 2−4.32 P A 2−0.41

= = …. Linearly interpolate
600−500 5.06−4.32 0.49−0.41

36 P N 2−4.32 P A 2
= =
100 0.74 0.08

P N 2=( 0.36∗0.71 ) +4.32=4.5864 kN P A 2 =( 0.36∗0.08 ) +0.41=0.4338 kN

Nominal power: PN = 4.5864Kn + 0.4338 = 5.0252kN

P∗C2 132∗1.3
Number of belts: Z = = =8.91 suggested: 9 Sk high
P N ∗C 1∗C3 5.0252∗0.98∗0.93
performance wedge belts

Minimum static tension per belt:

500 ( 2.04−C 1 ) ( PB + k ( v ) 2 )
T≈ , where, k  belt tension characteristics = 0.9
C 1∗Z∗V

500 ( 2.04−0.98 ) ( 171.6+ 0.19 (2.5 ) 2 )

≈
0.98∗9∗2.5

61
 v=( 2 πN )
2
= (60 2)
D 2 π 536 180
=2.224 m/sec ≈ 2.5 m/sec ⁡( for safty of wedge belt)

≈ 412.4.62+1.1875 ≈ 4126N

At initial installation: multiply by factor 1.3

Ti = 1.3*4126N = 5362.56N

Minimum static shaft load: Sq =2T sin ( B2 ) z

¿ 2∗5362.56 sin ( 149.28
2 )
∗9=93.095 kN

At installation: multiply by factor 1.3 therefore Sqi =1.3∗93.095 kN =121.02 kN

Geometry data: deep grooved pulleys: From appendixes, we can calculate the
geometry suitable of V-belt 17mm

Figure 5. 3: deep groove pulleys geometry

.3. Design of Crushing Roll Shaft

To determine the resultant forces acting on a particle of plastic bottle at the neck from
passing through two rolls with smooth surface. The following assumption were made:

bd = 14mm (datum width)

b1 = 19mm (top width) C = 8mm (groove thickness)

0
tmin = 22.5mm(thickness) α 1=34 (for dd1 140mm to 190mm of small pully) 62

α 2=380 (for dd2 > 190mm of large pully)

b =( Z−1 ) e +2 f for Z=5

The two rolls have the same peripheral-speed Acting om material plastic bottle
particle only one roll the stresses along the processing route (crushing zone) are
distributed uniformly, meaning the value pf plastic bottle particle relative deformation
at different point is proportional to the particle crushing degree. Under these
conditions:

( σ 6 mc
=
6 a' b), where; σ 6 = is the crushing at an arbitrary point along crushing or

process route.

σ 6= the maximum stress corresponding at the maximum strain direct to the center
line.

Figure 5. 45: processing route at catching the plastic bottle

The force acting on plastic bottle neck when passing through rolls:

63
( σ 6 mc
=
6 a' b )
, from this geometry analysis m c = a ' b'

According to the geometry, a ' b = R−R cos ( α ) = R ¿, but from the trigonometric
relations half angles,

sin ( )
1
2
x =
2√
1−cos x
 sin
2 x
2
=
2 ()(
1−cos x
)
 ( 1−cos x ) =2 sin
2 x
2 ()
Then by substituting, a ' b = R∗(2 sin
2
( 2x ))
mc = a ' c ' = o a' −o c ' = R cos θ−R cos α = R ( cos θ−cos α )

m c = R ( cos θ−1+ 1+ cos α )

= R(−1 ( 1−cos θ ) + ( 1−cos α ) )

From half angle relations: ( 1−cos x ) =2 sin2 ( x2 )

mc = R ¿

= R ¿ a ' c ' =2 R ¿

Where, α = catching angle of plastic bottle between rolls

R = roll radius

64
 L = length of roll

elemental force ⅆ F , along on a local elementary strip to length and angle ⅆθ , we can
be calculated as follows from equ –1.

6 ( )
σ b a' c'
= ' …we, know that, σ 6=
ab
ⅆF
ⅆA ( ) ,

( ) ( )
ⅆF ' '
aC
=σ∗ '
ⅆA ab

ⅆ F = σ∗
( )
a' C '
ab
'
∗ ⅆA

( )
' '
aC
Therefore, ⅆ F = σb∗ '
∗( ⅆ θ∗Rlo)
ab

= σb∗¿

= σb∗¿

Total force, F on the grinding roll or cutter, acting on the arc of crushing zone is
obtained by integrating above expression and is equal to the sum of all pressure
elements.

F σ α

∫ (¿ d F )=∫ ( ⅆσ ¿ ¿ Rl 0 )∗∫ ¿ ¿ ¿ ¿
0 0 0

65
 [ )] ¿
α

( ) (
−1 θ−sin ( θ )
σ∗R∗¿lo
()
F=¿= α 2
sin2 0
2

[ ( ( ) )]
α−sin ( α )
σ Rlo α −
F= 2 α
2∗sin
2

Generic thermo plastics: from the properties of polymers, the largest of the breaking
stress among the plastics, we selected polypropylene, pp to our design consideration:
from appendix:

so, breaking stress = 1.3 *tensile stress of pp

= 1.3 * 60 MPa = 78 MPa

Now, we can calculate the resultant force, F also, the angle ß the positioning of the
point of application of force resultant acting on the crushing roll, will have values
between, ßo =14.830, for α 0 = 200

the preliminary choice of the radius of the rolls 20cm and the length of roll crushing
mill taken 80cm.

[ ( ( ) )]
α −sin ( α )
F=
σ Rlo α 0−
2∗sin
2 α
2
, α0 = ( 180
0)
200∗π π
=
9

[ ( ( ) )] ()
π π
−sin
π 9 9
70 MPa∗200 mm∗800 mm∗ −
= 9 π
9
2∗sin 2
2

= 70 MPa*160mm2 [ π
9
−0.0601∗7.04567∗0.00001 = (11.2*424.92)
]
66
 = 4759.104N, the applied force to the crushing roll due to the plastic bottle.

The resultant force, F, which is directed parallel to the crushing rolls center can be
decomposed as the normal(radial) and tangential direction, to the point, K

F x =F sin β

,
F y =F cos β

next; one can neglect other forces on the particles of

material (own weight mg and air flow resistance Ra)
or may be taken into accounts for the calculation of
energy consumption to particle passing through the
work area between rolls.

+ ΣF =0 , F x + F f =T

= (F sin β + μ F ), F=¿4759.104 N, μ =0.54(coefficient of friction between the

plastic and metal surface)

= (4759.104 * (0.54 + sin (14.83o) = 3788.02 N

The power required of the particle through the grinding zone between two toothed
rolls which rotates at the same peripheral speed, v1 and v2, can be determined by:

p=T ∗ ( v +2 v ), ….v =v , so p=T ∗( 22v )= p=T∗v , (velocity can be calculated from

1 2
1 2
2

N3,

v=( ω∗r )=2 πNr =¿*198*200)/60 sec = 4.147 m/sec), therefore the power can be:
p=T ∗v = (3788N * 4.147 m/sec) = 15.7008Kw

To determine the application point of a resultant, force F, determine the forces

moment acting on crushing on the arc ab .

67
 M = {ⅆ F∗c c }
'
c c' Rsin θ

, =

= σ∗l 0∗R
2
α

∫ sin θ ⅆθ −∫ ❑
α sin θ sin2 ( θ2 )
0 0
sin
2
( α2 )
0

=σ ¿ l 0∗R 2*sin2 ( α2 )=70∗800 mm∗¿

0

= (70*32*100*301.5)

= 67544.26N-m or 67.544KN-m

To determine knife – cutter geometry the preliminary choice, h = 6cm or 60mm

Now, L=( R+ C s+ 26 cm ) = L=( 20+ 1+ 26 cm ) = 47cm

eUsing sine law: ( sin28 Cm

( 20 )
)=( 22Cm
sin ( θ )
), sin ( θ ) = ( 2228 )∗sin ( 20)=0.2687,
sin-1(0.2687) = 15.60

A Shaft subjected to bending and torsion only are those carrying spur gears V- belt,
sheaves, the power being transmitted cause the torsion, and the transverse force on the

68
element cause bending.

√[ ] [ ]
2 2
3 32 N KtM 3 T
D= +
π σe '
4 Sy

A size factor should be applied to the endurance strength because the shaft will be
quite large to be able to carry 132kw. We might select Cs = 0.75 from appendixes
figure size factor as an estimate

σe '=σe∗(C S)(C R)----------------- CR = reliability factor should also be

specified CR = 0.81 let us design for a reliability of 0.99, use CR = 0.81

σy
σe= -------------------------experimental data show the failure under
√3
combination of bending and torsion roughly follows the curve connecting these two
points, which obey the equation. therefore,

σy∗( C S )( C R ) σy∗( 0.81 )( 0.99 )

σe '= = =0.463 σy
√3 √3

from the primarily selected the diameter of roll shaft is 160mm

√[ ] [ ]
2 2
3 32∗2 2∗67544 3 3788
160 = + , stress concentration factor for bending
π 0.463 σy 4 σy
¿ the first term only , because this stress isrepeated

No factor is needed for torsional shear stress term because it is assumed to be steady,
and stress concentrations have little or no-effect on the failure potential. Then

[ ]
2
40.96∗10 6∗π 1 2 2
= 2 (62545.8 +0.75∗3788 )
64 σy

9
2 59.23∗10
σy =
4.046∗1010

69
 σy=1.21 MPa

For all cutter around the roll shaft, Z = 30so, the yield stress among the cutter will be
summation, therefore;

σ y T =30∗1.21=36.3 MPa

The deflection of roll shaft from bearing force analysis

R A =√ R2Ay + R2Ax  R A =√ 112.78 + 92.25 =145.31 kN

2 2

R B=√ R2By + R2Bx  R B=√ 30.47 +12.044 =32.764 kN

2 2

Deflection between A and B:

Assume max deflection at x = a/2 And deflection y ≤ 10mm

y=
MB
6 EI[6 a+
3 a2
L ]
a a3
−2 L −
2 L

10=
62545
6 EI[6∗400+
3 ¿ 4002
800
−2800
400 400 3
2
−
800 ]
6
6 EI =−6254.5 ( 40000−8000 ) 6 EI =25.02∗10

70
 π 2 π 2 2
For solid shafts, I = r = ¿ 80 =10053 mm 6 E(10053)=25.02∗106
4 4

250.2∗106
E= =4.148 GPa
60318

Consider loaded in bending by distribution load on the roll shaft. the stiffness
constraint requires that is not deflect more than 10mm. the objective to it achieve this
with minimum mass, table below summarizes the design requirements.

Table 5.3: Design requirements for light, stiff roll shaft according bending moment

Function Crushing the plastic solid waste

Constraints Bending stiffness σ* specified length L

Objective Minimize mass m of the roll crushing shaft

Free variable Choose of material

Mass of the crushing shaft

Outer radius(R)s

The objective function for the mass of crushing shaft

m=( π r 2)lρ−−−eqn .1

Its bending must be at least σ *

C1 EI
σ= 3
≥ σ *--------- C 1= depends only on the distribution of the loads
L

from useful solution for standard beam

384
C 1=
5

( )( )
2
384 E πr
σ* = −−−−eqn 2
5 r2 4

71
we can reduce the mass by reducing outer radius but only so far that the stiffness constraint is
still met, using the last two equation to eliminate outer radius, in the objective function gives

( )( 4π )
3
2 5 L
r=
384 E

m= ( 5 σ∗L3 4
384 E π )
lρ ¿ ( 384
20
σ∗L ) ( l ) ( )
3 ρ
E

( 384
20
σ∗L )−−−−function costraint
3

( l )−−−−geometry constraints

( Eρ )−−−−−material constraint

The quantities σ *, L, C1 are all specified, the only freedom of choice left is that of the
material, the index is the group of material properties, which we invert such that a maximum
is sought the best material for a light stiff roll crushing shaft are those with the greatest value.

E
M p 1=
ρ

E
So, a selection based on the index M = together with the property limit E> 4.2GPa
ρ

The material contained in the search region because the candidate for the next stage of the
selection process.

72
 Figure 5. 5: young's modulus density material selection

E
We seek the subset of materials that have high and E , we need the E−ρ chart, a
ρ
guideline of slope 1 is drawn on diagram, material above this line have higher values of M 1.
They are identified in the figure as composite (particularly CFRP) and certain engineering
ceramics, metal too. they are too heavy (even magnesium alloys), which are the lightest
polymers are out, they are hot stiff enough.

Table 5. 4: materials for roll crushing shaft

material E GPa Comment Relative cost per
M p 1= ( )
ρ m3 unit volume
Mg

Mg alloy 2.8-3 Stiffness & lightness 4

Ti alloy 2.3-4 Good M but expensive 400

CFRP 5.2-6 Good but not available 200

Zinc alloy 1.2-1.7 Low material index 2.5

73
So, our design and optimization of the roll crushing shaft the objective to its achieve this with
minimum mass has Magnesium alloys are materials of interest mostly due to their high
strength-to-weight ratios, exceptional machinability and low cost. They have a low specific
gravity of 1.74 g/cm3 and a relatively low Young's modulus (42 GPa) compared to other
common alloys such as aluminum or steel alloys.so the frame legs has magnesium alloy.
the mechanical properties of these alloy exhibit a moderate yield strength (Y.S.) of 159 MPa
and an ultimate tensile strength (U.T.S.) of 253 MPa.

Check: 36.3MPa<159 MPa so our design is satisfied.

.4. Design of Spur Gear

A design procedure that accounts for abending fatigue strength of the gear teeth and
the pitting resistance called surface durability. Some overall objectives of a design are
listed below. The resulting device should:

 Be compact and small

 Operate smoothly and quietly
 Have long life and Be low cost
 Be easy to manufacture
 Be compatible with the other elements in the plastic crushing machine such as
bearing, shaft, the housing

Input data: an electric motor transmits 132kw to the pinion at 198rpm

 the gear must operate at 195 rpm to 205 rpm or 200 ± 5 rpm
 the gear unit will be closed and commercial quality
 commercially hobbled (quality number A11)
 full-depth
 involute gears are to be used in the metric system
 the maximum Centre distance is to be 470 mm

198 rpm
Nominal-velocity ratio: v R= =1
198 rpm

Design-power: Overload factor (Ko): used to compensate for situations in the which

74
in actual load exceed the transmitted load Ft. from appendixes XI, Gives some
suggested value for Ko:

KO = 1.25-------- for uniform power source and light shock for aplastic shredder
machine

Pd = (1.25) *132kw = 165kw

From appendixes of spur gear figure of design power transmitted versus pinion speed
for spur gear with different pitches and diameters

m = 8 is reasonable trial module, then

Dp = 470mm NP = DP/m = 470/8 = 58.75

Dg = 470mm N g= 470/8 = 58.75 Ng = Np (VR) = 58.75(1) = 58.75 (use 60)

Final out speed: ng = np (Np/ Ng) = 198rpm (60/60) =198rpm

Center distance: C = (Np+ Ng) *m/2 = (60+60) *8/2 = 120*4 = 480mm

1000∗132 kw
Transmitted- load: Wt = (1000*P)/Vt = = 27.088kN
4.783 m/ sec

π n p D p π ( 470 ) (198)
Pith line speed: Vt = = =4.783 m/sec
6000 6000

Face width: Let’s specify the nominal F =12*m = 12*8=96mm

Factors in stress analysis:

 Specify the type of material for gears and elastic coefficient(cp)

Gear and Pinion material = steel (steel modulus of elasticity = 2*105MPa)

Elastic- coefficient (cp): the elastic properties of the materials for the pinion and gear
are known from AGMA standard 2001. (Cp= 191)

75
  Quality number (Au): using appendixes table of recommended AGMA quality
number. (For plastic crasher machine Au = 11)
 Dynamic factor (Kv): from appendixes figure of Dynamic factor vs pitch line
velocity with combination of the Quality number, reading (Kv = 1.42)
 Bending geometry factors for pinion and gear (J): from appendixes figure of
geometry factors (J) vs no of teeth for 200 full depth teeth spur gear: standard
addendum. (Jp = 0.44, JG = 0.44)
 Pitting geometry factor(I): from AGMA standard 2001 of geometry factor (I)
vs gear ratio (I = 0.09)
 Load distribution factor (Km): we will use the following equation for
computing the value of Km: reflects the amount if mating gear alignment
Km = 1+ Cpf+ Cma where: Cpf = pinion proportion factor
Cma = mesh alignment factor

Cpf = pinion proportion factor is dependent on the actual face width the pinion and on
the ratio face width to the pinion pitch diameter.

F = 96mm, Dp = 470mm

F/ Dp = (96/470) = 0.2, so we can use the curve F/ D p = 0.5, it satisfies (F/ Dp) < 0.5
from appendixes Cpf curve, Cpf = 0.05

 mesh alignment factor (Cma): Our design considerations open gearing, so

Cma = (0.2471+0.0167F- 0.765*10-4F2) = (0.2471+0.0167*96-0.765*10-4*96)2= 0.3

Or we can read from curve Cma= 0.3

Compute: Km = 1+ Cpf+ Cma = 1+ 0.05+ 0.3= 1.35

 Size factor (Ks): attempt account of any non- uniformity of the material
properties. It depends on the tooth size, diameter of parts and other tooth and
gear dimension.

From appendixes of AGMA standard 2001, suggested size factor (Ks = 1.15)

76
  The rim thickness factor (KB): for our design of spur gear, specify a solid gear
blank. So, (KB = 1)
 Service factor (Sf): typically, from 1.00 to 1.5, based on uncertainty of data, for
our design spur gear, there is no unusual uncertainty, let (Sf = 1)
 Reliability factor (KR): from appendixes table of recommended AGMA
reliability, for our design, specify a reliability of 0.99, (KR = 1)
 Design life: can be computed using equation
Nc = (60)L(n)(g), where, Nc = expected no of cycle of loading
L = design life in hour
g = no of load application

The plastic crashing machine will be fully utilized in an industrial environment we

Choose a life of L = 20000hrs using appendixes AGMA recommended design life.
Each tooth sees one load cycle per revolution, g = 1

Then: Nc = Ncp = Ncg = (60)L(n)(g) = (60) (20000) (198) (1) = 237.6*106 cycles

 Determine the stress cycle factor for bending: YNp = YNg = 1.67 from
appendixes stress cycle factor curves Pitting: ZNp = ZNg = 1.12

Pinion contact stress: As with equation for bending stress in gear teeth, several
factors are added to the equation for compact stress as shown below. The resulting
quantity is called the compact stress number, Sc

Sc = ¿ …

191∗27088∗1.25∗1.15∗1.33∗1.42
= ( )=818.817 MPa
96∗470∗0.09

Sc is used to compute contact stress for both the pinion and the gear: they are equal. It
is not correct to use the diameter of gear.

Adjustment for number of cycles, YNp = YNg = 1.67 and ZNp = ZNg = 1.12

( Sac−200.6 ) 200.6
Brinell hardness ¿ =731.09− =239HB
2.22 2.22

77
Required: Sacp= [ ( Sc )( SF ) ( KR )
ZNp ]
=[
818.817∗1∗1
1.21
]=731.09 MPa

Using Sacp = 731.09MPa, appendixes the required hardness = HB for Grade 1

Grade 1: is considered to be the basic standard and will be used for our design
purpose of spur gear, not required higher degree of control of the microstructure, alloy
combination, greater cleanness prior hear treatment, non-destructive test performed.

HB239 for through-hardened Grade 1 steel, this is acceptable but near the upper of
recommended range.

Material specification: from properties of carburized steels, we selected near to the

HB 239  241 Brinell hardness (HB)

material- designation: SAE 4118 DOQT 300; HB 241;

SU = 869MPa (ultimate strength), SY = 869MPa (yield strength)

21 --- elongation

Case hardness (HRC) = 62

Check other- stress: The contact stress for the gear and the bending stress for the
pinion and the gear are expected to require less material hardness and strength;

sc ( sF ) ( k R )
 Required Sacg ¿ =731.09 MPa
zR

The design analysis method used here is based primarily on AGMA standard 2001.
However, because values for some of the factors are not included in the standard, data
from other sources are added.

The following equation will be used in this design procedure

Bending stress (St) = W t ( K o ) ¿ ¿

78
 s tp ( s F ) ( k R ) 220.89∗1∗1
Required Satp ¿ = =132.27 MPa
Y Np 1.67

It is obvious that bending stress requires for lower hardness for the gear teeth, less
than HB 241. The stress in the gear always less than in the pinion. So, it will obviously
be safe as well.

79
Table 5. 5: Design of spur gear specification

Design of spur gear

Application: power transmitted of roll crasher

Input data values Factors in design analysis values

Input power 132kw Pinion proportion factor (Cpf) 0.05

Input data 530rp Type of gearing Open

m

Module 8 Mesh alignment factor (Cma)

No of pinion teeth 60 Alignment factor (Km) 1.35

Desired output speed 198rp Over load factor (Ko) 1.25

m

Computed no of gear 58.75 Size facto r(Ks) 1.15

teeth

Chosen data of gear teeth 60 Rim thickness factor (kB) 1

Computed data Dynamic factor (kU) 1.42

Actual output speed 198 Service factor (sF) 1

Gear ratio 1 Reliability factor (kR) 1

Module: pinion 8 No of load cycles (Np=Ng) 60

Gear 8 Bending stress factor 1.67

(YNP=YNg)

Center distance 48mm Pitting stress cycle (ZNp=ZNg) 1.12

Pitch line speed 4.873 Stress analysis

m/s

80
 Transmitted load 27088 Bending: contact stress 818MPa

Secondary input data Required 731.09MPa

Face width 96mm Pitting: bending stress 220MPa

F/Dp 2 Required 132.27MPa

Recommended ratio 1 Material SAE 4118

DOQT300:H
B241

Elastic coefficient 2*105

MPa

Quality no 11

Bending geometry 0.44

Pitting geometry 0.

.5. Design of Main Shaft

In order to design solid rotating shaft under combined cyclic bending and steady
tortional loading limited for ASME design code for the design of transmission
shafting can be used. The ASME procedure ensure that the shaft can be used.

Input data: first determine the

ratio of belts in

T1
=ⅇ μ ,T 1=T 2 ⅇμ
θ θ

T2

T1
¿ T 2= μθ
ⅇ

81
Power transmission = 132kw

Shaft speed 198rpm

Pressure angle = 200 µ = (0.54) coefficient of friction b/n wedge belt and
pully

Shaft is to be machined from SAE 1144 OQT 1000 steel (Tensile strength = 662MPa,
yield strength = 469MPa, and endurance limit = 326MPa)

121.02
Θ: angle of contact for our design θ = 149.50* π/1800 = 2.6 and T 2= = 33kN
ⅇ0.54∗2.61

torque on the pully in the term of the belt tension:

T = (T1- T2) *rp = (121.02 – 33) *250/1000 = 22kNm

Force on gears experience both radial and tangential loading is as shown above
diagram. The tangential load is given by Ft = 27.08kN

The radial load is given by Fr = 27.08*tan (20) = 9.856kN

The vertical loading diagram:

(T1 + T2) = T = 121.02 + 33 = 154.4kN , θ = 30

 ΣF=0 ,∑ F y =0

(T )cos (30)+ F r=R Ay+ R By

154.4(cos 30)+ 9.856=R Ay + R By ;  R Ay + R By=143.25 kN−−−1

82
  ΣM=0 ,∑ M A =0

(T)cos (30) * 0.3 + 1 * RBy = 0.3* F  133.4∗0.3+ R By=2.957+67.54

R By=−37.07+67.54=30.47 kN

Now, we can solve; RAy from equ.1  R Ay =143.25 – 30.47=112.78 kN

 The bending moment

M CV =0.3∗180.32−1.3∗37.07−1.6∗9.856−67.54
¿−9.8646 – 67.54=−77.4 kNm

M DV =133.4∗1.6 – 1.3∗180.32+ 11.121−67.54

¿ 9.855−67.54=−77.395 kNm

M S =¿)

¿−9.85+67.54=57.68 kN

Horizontal loading diagram:

 ΣF=0 ,∑ F x =0

(T )sin(30)+ F t=R Ax+ R By

154.4(sin 30)+27.08=R Ax + R By ; R Ax + R By=104.28 kN −−−2

83
  ΣM=0 ,∑ M A =0

(T)sin (30) * 0.3 + 1 * RBy = 0.3* Ft  133.4∗0.3+ R By=35.204

R By=35.204−23.16=12.044 kN

To calculate R Ax from equ.2: R Ax=104.28−12.044=92.25 kN

 The bending moment

M Cx=0.3∗92.25+1.3∗12.04−1.6∗27.08=0

M Dx =1.6∗77.2+120+3.6132=0

M S =0.8 Tsin30−0.5∗92.25+0.5∗14.044−0.8∗27.08

¿ 15.635−15.642=0

The resultant bending moment diagram can be determined by calculating the resultant
bending moment at each point

|M C|=√77.3952 +0 2=77.395 kNm

|M D|= √77.4 2+ 02=77.4 kNm

The shaft is to be machined from SAE 1144 OQT 1000 steel and endurance limit of
the test specimen; if unknown can be estimated using:
σe’ = 0.504 σuts
The ultimate tensile strength for 662 MPa and its yield strength of 469 MPa.
A series of modifying factor arc applied to endurance limit of test specimen for
various effect such as: size, load, and temperature(oC).

84
 σe = Ka* Kb* Kc* Kd*Ke* Kf* Kg* σe’
where: Ka = surface factor
Kb = size factor
Kc = reliability factor
Kd = temperature factor
Ke = duty-cycle factor
Kf = fatigue stress concentration
Kg = miscellaneous effect factor
σe’ = endurance limit of test specimen

Surface – factors: (table-5.3, pp

110)

σe’ = 0.504 σuts, for σuts ≥ 1400 MPa

= 0.504*662
= 333.648MPa
The surface finish factor is given by: Ka = a* (σuts) b , note that values for a and b can
be found in table 5.3.
Ka = 57.7* (662)-0.718
= 0.544

Size factor: can be calculated from:

Kb = (1.85*d-0.19), assume diameter of the shaft is 85 mm

= 1.85*(z=20)-0.19 = 1.047

Temperature factor (Kd): can be taken as 1, by assuming the operating temperature is

between -57o C and 204 oC.

Duty-cycle factor (Ke): used to account for cycle loading experienced shaft such as
stops and starts, transient overloads, shock loading, and require prototype fatigue
testing for its qualification. It taken as 1.

Fatigue stress factor (Kf): used to account for stress concentration regions such as

85
notches, holes, keyway, and shoulder. And it is given by:

Kf = 1/Kf,  Kf = 1+q(Kt-1), Where; q = notch sensitivity

Kf = geometric concentration factor

Value for the notch sensitivity and typical geometric stress concentration factor is
taken from appendix, assume fillet radius of 3mm.

(D/d) = ((3+3+20mm)/20mm) =
1.3

(r/d) = (3/20) = 0.15

Kt = 1. 61

Notch sensitivity factor index for q, 1000 MPa material with notch radius 3mm.

q = 0.88

so, Kf (component fatigue stress factor): = 1+ q (Kt -1)  1 + 0.88 (1.61 - 1)

= 1.5368, therefore; Kf = 1/Kf = (1/1.5368) = 0.65

Miscellaneous factor (Kg): to account for residual stresses, heat treatment, corrosion,
environment, and unusual loading Kg is taken as 1. Here, the endurance limit can now
be calculated from:

σe = Ka* Kb* Kc* Kd*Ke* Kf* Kg* σe’

86
 = (0.544*0.443*1*1.047*0.65*1* 333.648MPa) = 326 MPa

As a well-known material I has been selected is subjected to known loads the factor of
safety Can be taken as ns = 2.

The diameter Can now be calculated from the ASME – Equation:

[ √( ) ( )]
1
32 n s M
2
3T
2 3
d= +
π σe 4 σy

kw∗2 π
Torque= power∗ω ¿ 132 190 ¿ 2625.48 kNm
60

[ √( )]
1

)(
2 2 3
32∗2 77.4∗1000 Nmm 2625.48∗1000 Nmm
d= +
π N 4∗469∗10 6 N
326∗106 2
mm mm
2

1
d= ( 4.841∗106 ) 3 =78.89 mm

As this value is close to the assumed value used evaluate the size and fatigue stress
factor, further iteration is not necessary. For manufacturing convince, it may be
necessary diameter this to the nearest standard size as used Within the company, in
this case 80mm is used.

.6. Design of shaft between two pullies

F1 F 22.2
=ⅇ μ , F 2= μ1 = 0.54∗2.61 =5.423 kN
θ

F2 ⅇ ⅇθ

87
∑ F y =0

( T 1+T 2 ) sin ( 60 ) + F 1+ F 2 cos 30=R Ay + R By

( 33+121.02 ) sin 60+ ( 22.2+5.43 ) cos 30=R Ay+ R By ;

R Ay + R By=157.3135 kN−−−1

∑ M A =0

0.2∗(T 1+T 2) sin 60+0.7∗( F 1+ F 2)cos 30=0.9∗R By

0.2∗(33+121.02)sin 60+ 0.7∗(5.45+22.2)cos 30=0.9∗R By

26.677+16.762=0.9∗R By  R By=48.265 kN

Then, from equ.1  R Ay =157.31 – 48.265=109.045 kN

88
Horizontal plane:

∑ F x =0 , ( T 1+T 2 ) cos ( 60 )=R Ax + R Bx +( F 1+ F 2cos 60)

( 33+121.02 ) cos 60= ( 22.2+5.43 ) cos 60+ R Ax+ R Bx ;

R Ax + R Bx=63.155 kN −−−−−−2

∑ M A =0

0.2∗( T 1+T 2 ) cos 60=0.7∗( F 1+ F 2 ) cos 60+0.9∗R Bx

0.2∗( 33+121.02 ) cos 60=0.7∗( 5.45+22.2 ) cos 60=0.9∗R By

15.402=9.667+0.9∗R Bx  R By=6.378 kN

Then, from equ.2, R Ax=63.155−6.378=56.77 kN

Bending moment of vertical plane diagram

∑ M By =( 0.2∗109.045 ) + ( 0.5∗14.825 )−0.7∗48.265

¿ ( 21.809 ) + ( 12.338 )−33.7855=0.03 kNm

∑ M Cy=( 0.7∗109.045 )−( 0.5∗24.825 )−0.2∗48.265

¿ 54.266 kNm

Bending diagram of horizontal plane

89
∑ M Bx =( 0.2∗56.77 ) + ( 0.5∗13.825 )−0.7∗6.378

¿ 25.2895 kNm

∑ M Cx=( 0.7∗56.77 )+ ( 0.2∗6.378 ) −0.5∗93.51

¿ 3.214 kNm

Resulting of bending moments: |M B|=√ 25.2895 +0.03 =25.29 kNm

2 2

|M C|=√3.214 2+ 54.2662=54.36 kNm

So, we can design the shaft with maximum bending moment: M C =54.36 kNm

[ √( ) ( )]
1
32 n s M 2 3T 2 3
d= +
π σe 4 σy

kw∗2 π
Torque= power∗ω ¿ 132 536 ¿ 7409 kNm
60

[ √( )]
1

)(
2 2 3
32∗2 54.36∗1000 Nmm 3∗7409∗1000 Nmm
d= +
π 6 N 4∗469∗106 N
326∗10
mm 2 mm2

[ ]
1
1
64 64
d=
π
√ −8 4
2.78∗10 +1.8717∗10 3 d=( ∗0.0137) 3 =77.94 mm
π

As this value is close to the assumed value used evaluate the size and fatigue stress
factor, further iteration is not necessary. For manufacturing convince, it may be
necessary diameter this to the nearest standard size as used Within the company, in
this case 80mm is used.

90
Table 5. 6: design of shaft specification

Design of shaft
Application: drive for a plastic crushing machine
Shaft material specification: SAE 1144 OQT 1000 steel
Input data values Source
Tensile strength (σt) 662MPa Given
Yield strength(σy) 469MPa Given
Size factor (Cs) 1.04 referenced
Reliability factor (CR) 0.99 referenced
Modified endurance strength (σe,) 326MPa computed
Stress concentration (Kf) 1 referenced
Factor of safety (N) 2 given
Temperature factor 1 referenced
Duty cycle factor 1 referenced
Surface factor 0.544 computed
Miscellaneous factor 1 referenced

Shaft loading data: bending and tortional

Bending moment components Mx = 0 computed
My = 77.4kNm computed
Combined bending moment M = 77.4kNm computed
Torque T = 2625.48kN computed
Shaft loading data: vertical shearing force only
Shearing force components Vx = 27.08kN computed
Vy = 9.856kN computed
Combined shearing force V = 28.818kN computed

.7. Bearing Selection

Both radial and thrust loads are exerted on a bearing, the equivalent load is the
constant radial load that would produce the same rated life for the bearing as the
combined loading. The method of computing the equivalent load, P, for such cases is
presented in the manufacturer’s catalog and takes the form.

91
Figure 5. 6: flow chart of bearing selection

92
Equivalent Load with Radial and Thrust Loads

P = VXR + YT …………………………………………. wheere

P = equivalent load V = rotation factor

R = applied radial load T = applied thrust load

X = radial factor Y = thrust factor

Input data -to carry a radial load of 1850 Nm and a thrust load of 675 Nm.

-The shaft is to rotate at 1150 rpm, and a design life of 20 000 h is desired.

-The minimum acceptable diameter for the shaft is 3.10 in.

Use the procedure outlined above.

Step 1. Use X = 0.56 and assume Y = 1.50.

Step 2. P = VXR + YT = (1.0) (0.56) (1850 Nm) + (1.50) (675 Nm) = 2049 Nm.

Step 3. The required basic dynamic load rating C is found from Equation

Ld = (h)(rpm) (60 min/h) = (20 000 h) (1150 rev/min) (60 min/h) = 1.38 * 109 rev

C = Pd (Ld/106)1/k = (2049 Nm) (1.38 * 109/106)1/3 = 22 812 Nm

Step 4. From appendices of a single-row, deep-groove ball bearing, we can use

bearing number 6316 having a bore of 80 mm just larger than the stated Dmin = 65mm

Bearing6316: bore = 80mm, outer diameter = 170mm

Width, B = 39mm, max. fillet radius = 2 mm

Max. shaft shoulder diameter = 91 mm bearing mass = 3.6 Kg

93
 .8. Design of Hopper

Figure 5. 76: hopper geometry

Volume of hopper: 𝑉 = 𝐻𝐵 (𝐿1 + 𝐿2)

𝑉 = 0.1368𝑚3

Our design based on the polypropylene with density 0.92g/cm3. Therefore:

The mass of pp that fill the hopper = volume of hopper ∗ 𝜌

= 0.1368m3 ∗ 920kg/m3 = 𝟏𝟐𝟓. 𝟖𝟓𝟔𝒌𝒈

.9. Design of Fasteners

5.9.1. Design of Key

A key is a machinery component placed at the interface between a shaft and the hub
of a power-transmitting element for the purpose of transmitting torque. The key is
demountable to facilitate assembly and disassembly of the shaft system. It is installed
in an axial groove machined into the shaft, called a key seat.

94
Figure 5. 8: flow chart of key selection

Figure 5. 97: key profiles

95
Table 5. 7: key selection and evaluation

Requirements Values Square Rectangular Plain GN Pin-

key taper head key
Easy to connect or 8 1 1 0 0 1
disconnect
Transmit power 7 0 0 1 1 0
without loss
Perfect alignment 9 1 1 0 0 1
Reduce 4 1 1 0 1 1
transmission of
shock loads
No-projecting 5 0 1 1 1 1
parts
Grade 33 19 24 2 12 10

Stress in key: There are two basic modes of potential failure for keys transmitting
power: (1) shear across the shaft/hub interface and (2) compression failure due to the
bearing action between the sides of the key and the shaft or hub material. The analysis
for either failure mode requires an understanding of the forces that act on the key.
Figure below shows the idealized case in which the torque on the shaft creates a force
on the left side of the key. The key in turn exerts a force on the right side of the hub
key seat. The reaction force of the hub back on the key then produces a set of
opposing forces that place the key in direct shear over its cross section, W * L.

Stress analysis to determine key length: AINI lists dimension for a large no. of
standard rectangular key and table below provides a sampling:

2∗T
Minimum required length of key: L min= ,
T d −D w

assume L min=40 mmand T d=2∗T /(L min∗D w)

¿(2∗2846.78∗1000 N −mm)/40 mm∗16 mm

¿(7116.95 /40)MPa , T d=176.7 MPa

96
 In design, we can set the shear equal to a design in shear for the maximum shear
stress theory of failure.

T d=(0.5 S y / F os ), note that , Fos=1.5

Td = Sy/ (1.5*2) = Sy/3 and we know that, Sy = 3* Td = 3*180 MPa = 540MPa

Selecting material for key from appendixes key materials used for keys.

Carbon – steel (SAE) 1095, Sy = 572 MPa

Let us check our design stress for compression: - minimum required key length for
compression is given by: Lmin = (4 ∗ 𝑇)/ (𝜎 ∗ 𝑑 ∗ 𝐷 ∗ 𝐻)

= (4 ∗ 2846.78 ∗ 1000)/ (572𝑁/𝑚𝑚2 ∗ 50𝑚𝑚 ∗ 10𝑚𝑚)

= 40.346mm

So, to safe design take: Lmin = 55mm, either the shaft or the hub has a lower yield –
strength than key:

Fillet radius = 1/16 inch = 1.5875 = 1.6mm

5.9.2. Design of Bolt and Nut

Advantage of bolt: screwed joint and highly reliable in operation

 screwed joint and convenient to assemble and dissemble

 a wide range of screamed joint may be adopted to various operating condition
 screws are relatively cheap to produce due to standardization and highly
efficient manufacturing processes: the strength of the screwed joint is not
capable with that of riveted or welded joints.

Design for bolt on the support from the shear stress and bending stress are:420Mpa
and 84Mpa t = 420mpa, n = 4, σ = 84Mpa

Then to find the major diameter of bolt: Ps = π/4*d2*σ*n, in the case of bolt on the

97
support frame Ps is the summation of tensions and the total weight load on the frame.

Ps = T1 + T2 + W = 1046.186N + 134.569N + 5033.33442N = 6214.089N

Then, d = (4Ps/ π* σ*n) = (4*6214.089/ (84*4* π))0 = 4.85mm

Table 5. 1: Design dimensions of screw threads, bolts and nuts according to IS: 4218

Depth of Stres
Pitch Major Pitch
Minor or core thread s
Designation diamete diamete
diameter (bolt) mm area
mm r r
mm2
bolt nut
(1) (2) (3) (4) (5) (6) (7) (8)
Coarse series
M 0.4 0.1 0.400 0.335 0.277 0.292 0.061 0.074
M 0.6 0.15 0.600 0.503 0.416 0.438 0.092 0.166
M 0.8 0.2 0.800 0.670 0.555 0.584 0.123 0.295
M1 0.25 1.000 0.838 0.693 0.729 0.153 0.460
M 1.2 0.25 1.200 1.038 0.893 0.929 0.158 0.732
M 1.4 0.3 1.400 1.205 1.032 1.075 0.184 0.983
M 1.6 0.35 1.600 1.373 1.171 1.221 0.215 1.27
M 1.8 0.35 1.800 1.573 1.371 1.421 0.215 1.70
M2 0.4 2.000 1.740 1.509 1.567 0.245 2.07
M 2.2 0.45 2.200 1.908 1.648 1.713 0.276 2.48
M 2.5 0.45 2.500 2.208 1.948 2.013 0.276 3.39
M3 0.5 3.000 2.675 2.387 2.459 0.307 5.03
M 3.5 0.6 3.500 3.110 2.764 2.850 0.368 6.78
M4 0.7 4.000 3.545 3.141 3.242 0.429 8.78
M 4.5 0.75 4.500 4.013 3.580 3.688 0.460 11.3
M5 0.8 5.000 4.480 4.019 4.134 0.491 14.2
M6 1 6.000 5.350 4.773 4.918 0.613 20.1

From table above design dimensions of screw tread, bolt and according to 1S:42’18

98
We select M5: (pitch=0.75, major or nominal diameter=5) Nut and bolt (D) in mm.

✓ effective or pitch diameter (dp)=4.480mm, Nut and bolt (dp) in mm

✓ minor or core diameter(dc)mm for bolt=4.019

✓ minor or core diameter(dc)mm for nut=4.134

✓ depth of tread (bolt)mm=0.491

✓ stress area =14.2

.10. Design of Frame

The legs must be solid (to make them thin) and as light as possible. They must
support the plastic crusher roll shaft and whatever is placed upon it without buckling.
What materials could one recommend?

Table 5. 2: Design Requirements for frame Legs

Function Column (supporting compressive loads)

Constraints Length L specified

Must not buckle under design loads
Must not fracture if accidentally struck
Objectives Minimize mass,
maximize thickness
Free width of legs, w
variables Choice of material

The leg is a slender column of material of density ρ and modulus E. Its length, L,
and the maximum load, F, it must carry are determined by the design: They are
fixed. The radius r of a leg is a free variable. We wish to minimize the mass m of
the leg, given by the objective function.

99
 m = A ∗ L ρ, m = b ∗ w ∗ L ρ

Subject to the constraint that it supports a load P without buckling. The

elastic buckling load Fcrit of a column of length L and square rectangular is

( )( )
2 2 3
π EI π E bW
Fcrit= = 2
L
2
L 12

12 2
∗L
π2
∗1
3 b
W =Fcrit
E

using I = b*w3/4 where I is the second moment area of the column. The load F must
not exceed Fcrit. Solving for the free variable, r, and substituting it into the equation
form gives

m ≥b∗w∗L ρ

( )
1
12 2
∗L 3
π2
∗1
b
m ≥b Fcrit ∗L ρ
E

( )
2
L ¿ 1
( bl ¿ )∗ρ
m≥ ( π )
Fcrit 12 13
∗
b 3

E
1
3
¿

The material properties are grouped together in the last pair of brackets. The weight
is minimized by selecting the subset of materials with the greatest value of the
material index

1
E3
m≥
ρ

Figure below shows the appropriate chart: that in which Young’s modulus is plotted
against density ρ. The selection line for the index M has a slope of 3, it is positioned

100
so that a small group of materials is left above it. They are the materials with the
largest values of M and represent the best choice, provided they satisfy the other
constraint (a simple attribute limit on toughness).

101
 Figure 5. 10:young’s modulus-density chart

Table 5. 10: materials for frame leg

Materials for frame leg

materials M1 comment
Woods 3.4–6.3 Woods Inexpensive, traditional, but with
natural variability
Ceramic 4–8.9 Good M but toughness low and cost
s high
Mg alloy 2.8-3 Good as light as possible without
buckling
CFRP 4.8-7 Expensive and not availability

Magnesium alloys are materials of interest mostly due to their high strength-to-weight
ratios, exceptional machinability and low cost. They have a low specific gravity of
1.74 g/cm3 and a relatively low Young's modulus (42 GPa) compared to other
common alloys such as aluminum or steel alloys.so the frame legs has magnesium
alloy.t he mechanical properties of these alloy exhibits a moderate yield

102
strength (Y.S.) of 159 MPa and an ultimate tensile strength (U.T.S.) of 253 MPa.
the Young's modulus determined from the elastic slope of the tensile stress–strain
curve E=65 GPa.

Mass of the roll crushing shaft: m= A∗L ρ , were

π 2 π 2 2
A= r = 80 =5052 .55mm , L = 800mm and ρ=1740 kg/m 3
4 4

m=( 5052.55 ) ( 800 )∗1740 ¿ 6.996 Kg

Total mass roll crushing shaft: m=2∗6.996=13.992 Kg

force=13.992∗9.81=137.26 N

so, for one leg

132.26
F= =34.31538 N
4

We shall design the column for a critical load of: P cr=nd∗F 1=3∗34.31538=103 N

From end-condition constraints for Euler columns to be used with fixed-fixed: C = 4

For the rectangular columns, we specify a cross section h*b with h ≥ b, if the end
condition is the same for buckling in both directions then buckling will occur in
direction of the least thickness,

we assume b = 50mm and l = 700mm

12∗P cr L2 12∗103∗7002
Therefore; W= 2 3
¿ 2 3 3 ¿ 90 mm
π CE b π 4∗65∗10 ¿ 50

.11. Design of Sieve

Length of the sieve = length of the roll crushing shaft = 800mm

103
Radius of the shape of holes = 5mm; No of holes = n

A> ( π4 r ) n
2
 (800∗470)> ( π4 5 ) n
2

1961>n

So, we shall to 1800 holes on the sieve to filter out the debris plastic waste solid
otherwise it can recycle the plastic into the crushing roll shaft until to the required
plastic size of sieve.

CHAPTER SIX

6. PRODUCT DEVELOPMENT ECONOMICS

Manufacturing cost is a key determinant of the economic success of a product. In

simple terms, economic success depends on the profit margin earned on each sale of
the product and on how many units of the product the firm can sell. Profit margin is
the difference between the manufacturer’s selling price and the cost of making the
product. The number of units sold and the sales price are to a large degree determined
by the overall quality of the product. Economically successful design is therefore
about ensuring high product quality while minimizing manufacturing cost. DFM is
one method for achieving this goal; effective DFM practice leads to low
manufacturing costs without sacrificing product quality.

104
 .1. Machining Costs

6.1.1. Component Cost:

The components of a product (also simply called parts of the product) may include
standard parts purchased from suppliers. Examples of standard components include
motors, switches, electronic chips, and screws. Other components are custom parts,
made according to the manufacturer’s design from raw materials, such as sheet steel,
plastic pellets, or aluminum bars. Some custom components are made in the
manufacturer’s own plant, while others may be produced by suppliers according to
the manufacturer’s design specifications.

Table 6. 1: bill of materials and component cost of plastic crushing machine

Component Materials Product

Assembly
quantity

unit cost
materials
Purchase
s specification

labor

Total
)
d

(
Motor 1 _ 20 hp, single 6500 16 6516
phase ac
induction motor

Control unit 1 _ Protective 65 2.5 67.50

circuit switch
0

Bolts and 5 plain carbon M16*20mm 35 12 235

nut, washer steel 30C8

Pulley 4 grey cast Ø500, width 160 6 664

iron of Grade
FG 200 23.5

Ø180,

Spur gear, 2 SAE 4118 Ø470, face 120 8 256

pinion and DOQT 300; width 96 mm
gear HB 241

v-belts 4 fabric rubber SPB belt profile. 127 10 548

belt.

105
 Bearing 6 high carbon Ø120mm, NO 150 8 948
ASMA 6316
chromium
steel

Hopper 1 Sheet metal 1000*400*360 500 6 506

t=1.5 mm

Frame legs 4 Magnesium’ 90*50*700 mm 450 6 1824

s

alloy steel

Key 6 Carbon – 55*16*55mm 50 6 336

steel (SAE)
1095,

Roll 2 Magnesium’ Ø 260*1000mm 450 16 932

crushing s
shaft
alloy steel

Spline shaft 1 Magnesium’ Ø 80*1200mm 400 10 410

s

alloy steel

Total direct cost 8977 193 9170.5

0
.50

Overhead 500 50 550

charges

Total cost 9720.50

.2. Assembly Cost

Assembly costs: Discrete goods are generally assembled from parts. The process of
assembling almost always incurs labor costs and may also incur costs for equipment
and tooling.

106
Table 6. 2: assembly cost list

No. Component quantit Handling Insertion Total

y time time time

1. Motor 1 5 min 3 min 8 min

2. Belt 4 4 min 1 min 20 min

3. Shaft 2 3 min 2 min  10 min

4. Cutter/crushing blade 2 5 min 3 min 16 min

5. Frame - 1 min 2 min 3 min

6. Fasteners (key, bolt 16 1 min 1 min 32 min

& nut)

7. Bearing 6 3 min 1 min 24 min

8. Spur gear 2 2 min 2 min 8 min

9. Pulley 4 2 min 1 min 8 min

10. Sieve  1 1 min 2 min 3 min

11.  Control unit  1 1 min 0.25 min 1.25 min

12 Hopper  1 1 min 2min 3 min

     Total assembly time 136.25

min

    Total assembly cost 2 birr/min 272 birrs

107
 .3. Machining/ Manufacturing Cost

Manufacturing cost is the cost that is needed for production of the complement; it
includes the cost for the employee working in each production process and the
machine cost. The type of production and time taken on each is presented on the table
below.

Table 6. 3: manufacturing cost

Types or way of manufacturing Time taken in hour (Hr.)

welding 4

cutting 10

turning 8

facing 6

Tread cutting (internal and external) 12

drilling 6

rolling 2

bending 8

grinding 6

assembling 12

Painting 5

total 79

108
To calculate the employee cost the following assumptions are taken. A workshop man
works 26 day in month with average salary of 4600 Birr.

Payment per day = 4600/26 = 176.92 Birr/day and he work 8 hour per day.

Payment per hour = 176.92/8; = 22.115 Birr/hour. Therefore,

the total manufacturing cost = total working time (hour)*payment per hour

+ machine cost approximated as

= 2[total time taken (hour)*payment per hour], assuming both costs are equal

= 2[79*22.115] [(Birr/hour) *(hour)]] = 2*1747.115 Birr = 3494.23 Birr

.4. Design Cost

Design cost is a price given to the designer, who designs the machine which is paid to
the designer of the implement. We have designed the implement for partial fulfillment
of our mechanical Engineering degree program. But if this implement is going to be
manufactured in mass, we expect 10% from each soled implement.

.5. Total Cost of Complement

The total cost will be the sum of all the three costs. This is cost of accessories and
materials, manufacturing cost, and design cost. Adding a contingency cost of 10%:

Total cost = 1.1(9750+3494.23) =1.1(13,244.23) =14,5568.40 birr.

109
 CHAPTER SEVEN

7. RESULT AND DISCUSSION

In this chapter computerized method or Computer Aided Design analyses result have
been included. When we see result of the experimental sample of the solid waste of
polyethylene (PET) plastic crusher machine’s cutter or cutting blade is experimental
describes effectiveness of the materials selection we conducted on the experiment.

.1. Result

Figure 7. 9: Equivalent (von-mises) stress of frame

110
 Figure 7. 10: Total deformation of frame

Figure 7. 11: Equivalent (von-mises) stress of shaft

111
Figure 7. 12: Total deformation of shaft

112
Figure 7. 13: Equivalent (von-mises) stress of gear

Figure 7. 14: Total deformation of gear

113
Figure 7. 15: Equivalent (von-mises) stress of rushing roll shaft with welded blade

114
Figure 7. 17: Total deformation of crushing roll shaft with welded blade

Figure 7. 16: Equivalent (von-mises) stress of pulley

115
Figure 7. 18: Total deformation of pulley

116
 .2. Discussion

The maximum and minimum value of Von Misses stress finite element analysis result
it done by ANSYS workbench using FEM analysis applied material magnesium alloy
at the edge of cutting cutter the maximum applied force on the cutter is 77.4 KN.
When applied the force on the cutter crushing material as shown the result contour
plot, maximum equivalent (von misses) stress is indicating by red color, which has a
value of 0.39315∗10−5 MPa and the minimum value is 8.3331∗10−6 MPa it indicates
by blue color respectively. this analysis results the maximum von misses result is
much lesser than yield strength of the material that is 159MPa.

The maximum the total deformation of the cutting blade is having maximum value of
4.2776∗10−5 mm and the minimum value is 0 mm . The applied material is magnesium
alloy and the maximum deformation analysis result is 4.2776∗10−5 mm mm. that is
much less than maximum deformation of the material that is 10mm. Which indicate
the material of yield stress value is safe when we compared to the maximum von
misses stress result and maximum deformation.

the figure shown that the von misses stress and total deformation in the subject of
stress distributed on the surface of roll shaft and profile of cutter blade

117
 CHAPTER EIGHT

8. CONCLUSION AND RECOMMENDATION

.1. Conclusion

The results of this thesis, are obtained from the mathematical design analysis and
modeling of solid plastic waste crushing cutter/blade using ANSYS. Results with
design analysis method are done and similar results have been obtained with
reasonable accuracy.

So, this researcher has used ANSYS workbench to predict contact force of
mechanical components of cutter/blade to improve model of crushing/shredding
cutter. Generally, from this thesis work, the following conclusions can be drawn:

We can conclude that plastic is crushed with the help of plastic crushing machine
hence we also design and manufacture plastic crushing machine. Plastic is essential
part of our day-to-day life. But there is a big disadvantage of plastic, it is difficult to
decompose. So, we have to recycle the plastic and there are various methods for
plastic recycling. various papers we selected one method for plastic recycling and we
will make a machine which is used for plastic recycling. We studied how to design the
machine from literature review and we got many technical details about this machine
this is very helpful to us. The crusher machine crushed the plastics as per our
requirement. This project also helps in protecting the environment as it crushes the
plastic wastes. The crushed plastics which come out can also be used for recycling.

A plastic crushing machine was designed and successfully constructed. This was
aimed at solving the problems of indiscriminate dumping of plastic solid wastes. The
machine was evaluated for performance. Collected plastics wastes were crushed with
the machine and the results obtained reveal that the machine performance is
satisfactory. This machine when commercialized will meet the demand for plastic
wastes management.

118
119
 .2. Recommendation

From this thesis point view we would like to recommend that it is very important to
manufacture this plastic crushing machine and distribute to our areas(country) with
minimum cost and in light weight. In this regarded the Ethiopian mechanical
engineering have a great role on further design and development of this machine.
Finally, would like to recommend strongly that particular attention should be given to
design and manufacture this machine and distribute for our homeland by low cost.
Beside this, anyone who want to modify it, we would like to announce you to
redesign
a plastic crushing machine with another material like stainless steel, that cannot be
costly, light weight as well as harmless (health care). Finally, we recommend our
college, college of Electrical and Mechanical Engineering (AASTU) to support with
every material needs and suggestion so as to come with reality to our
project.

120
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