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Optimal Design AND Analysis OF TWIN Shaft Shredder

Engineering Statics (HITEC University)

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INTERNATIONAL JOURNAL OF RESEARCH AND INNOVATION

Subject: Mechanical Engineering IJRIME

OPTIMAL DESIGN AND ANALYSIS OF TWIN SHAFT SHREDDER

A.Venkata Rathnam1, U. Hari Babu 2.

1 Research Scholar, Department of Mechanical Engineering, QIS College of Engineering & Technology, Ongole, A.P. ,
India.

2 Professor, Department of Mechanical Engineering, QIS College of Engineering & Technology, Ongole, A.P. , India.

Abstract
Shaft shredder is a widely used machine to make chips from plastic or rubber wastes for recycling process; now a
days maximum of plastic products are mixture of original and recycled materials. The aim of this thesis work is to
develop twin shaft shredder with higher efficiency and life. Initially literature review and data collection will be done to
understand the approach and methodology which is useful for design, material selection and analysis process.
Theoretical calculations will be done to find stress & deformation. A 3D model will be prepared to conduct analysis
work to evaluate part to observe failure locations. Geometrical modifications will be done according to the obtained
results to reduce stress concentration and analysis will be done to evaluate results for comparison with previous
model; also various materials will be analyzed to suggest best material. In this thesis work stress, strain, deformation,
safety factor, natural frequency and harmonic response will be considered to conclude the project work.

KEYWORDS: Twin, Shredder, material selection, stress concentration, Deformation, Harmonic response.

*Corresponding Author: transporting the wastes to the recycling plants,

A.Venkata Rathnam, Research Scholar, wherein a huge amount of effort, time and money
Department of Mechanical Engineering, needs to be put in for transporting the wastes which
QIS College of Engineering & Technology, are clustered and are not in uniform shape or size. The
Ongole, A.P., India. waste materials need to be made into a uniform shape
Email: venkeyaleti@gmail.com for easy and effective transportation. This paper aims
in producing a mechanical crusher which would be a
Year of publication: 2017 helping hand for waste management. This crusher can
Paper Type: Review paper be used for crushing plastic and rubber scraps for
Review Type: peer reviewed reducing the space occupied by these while carrying it
Volume: IV, Issue: II to the recycling plants.

*Citation: A.Venkata Rathnam, Research Scholar,
"OPTIMAL DESIGN AND ANALYSIS OF TWIN SHAFT
SHREDDER " International Journal of Research and
Innovation (IJRI) 4.2 (2017) 805-813.
Introduction
In a country like India, waste management and
disposal of the waste seems to be a tedious task where
a huge amount of wastes has been generated due to
enormous consumption. There also lies an issue in
Plastic and rubber products are made in such a way
that there are lot of hollow space within them to carry
whatever it has been designed for. These materials if
carried just like that, would occupy more space and
would require huge containers and transportation cost
becomes an issue. These materials needs to be
arranged properly to increase the carrying capacity of
the vehicle and as the cans being an indefinite shape
needs to me made into uniform shape and size for easy
disposal. This is where the mechanical crusher comes
in to play. The crusher would crush the cans thus
reducing the gap between them and make them to
uniform size and shape so that the materials can be

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baled up according to the size of the crushing bin. The Thickness = 25
uniform size and shape of the materials can be
obtained by providing a bin onto which the material is Cutting force , CF = L x S x Tmax.
to be crushed. The crusher is designed to operate by
both mechanical and electrical means. L = length to be cut = 10 mm
Operating Mechanism
S = subject thickness = 0.5 mm
This crusher works on the simple mechanism called
crank and slotted lever mechanism. When the motor is T max = tensile / shear strength = 110 MPa. for pet
excited using a power source (i.e.3-phase power supply
in this case) the shaft starts to rotate which in turn CF = 10 x 0.5 x 110 = MPa.
rotates the pulley which is connected to the motor by
means of a belt drive. This pulley gives rotary motion
to the transmission shaft which in turn rotates the
crank plate that is attached to the main shaft. The
bearings in between the crank plate and pulley
ensures smooth power transmission.

The crank converts the rotary motion to the

reciprocating motion of the piston. The piston rod is
adjusted to deliver optimal crushing force required to
Figure 2: Free body diagram of shredder shaft
crush the material and as the piston reciprocates
inside the bin onto which the materials are placed or
RA =RB
fall one by one with the help of a hopper gets crushed
and acquires the shape of the bin. This crushed RA x 500 = (550 x 25) + (550 x 51) + (550 x 77) +
material can now be removed from the bin from the (550 x 103) + (550 x 129) + (550 x 155) + (550 x 181) +
bottom part by removing the base plate of the bin and (550 x 207) +(550 x 233) + (550 x 259) +(550 x 285) +
can be transported just as it is to the recycling plants. (550 x 311) +(550 x 337) + (550 x 363) +(550 x 389) +
(550 x415) + (550 x 440) = 2178000/500 = 4356 N
Cutting Table
Momentum =Force x distance

MC = 550 x 25

= 13750 N - mm

MD = 550 x 26

= 14300 N - mm

ME = 476.3 x 26

= 12383.8 N - mm

MF =476.3 x 25

Figure 1 : Cutting Table = 11907.5 N - mm

1. Side plates (MB) max bending moment at point F

2. Shaft
Ra = Rb = w/2 = (550 x 4)/2
3. Rotating Blades
4. Fixed Blades = 1100 N = 112.13 kg
5. Bearing holding plates
T = force x distance

OD = 150 mm 550 x 0.942 meters

TD = 32 mm = 518.1 N- m

Number of teeth = 6 So we need to take = 40 HP motor

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K = effective length factor 2.0

BENDING STRESS F=

σ=fe (ba.m.y)
F = 3.142×203×3.658/(2×50)2
Fe = tangential force on tooth = 4356 N
F=
σ= bending stress = 30.061 N/mm2
F= 6.305 N
Y = Lewis form factor
Introduction To Pro-E
M = module =1, Where
Pro/ENGINEER Wildfire is the standard in 3D product
b = half width of the contact surface design, featuring industry-leading productivity tools
that encourage finest methods in design while
σ= = 11616 MPa providing compliance with your industry and company
standards. Integrated Pro/ENGINEER CAD/CAM/CAE
Surface durability = σw2.f/(π.6.1) solutions allow you to design faster than ever, while
widening innovation and quality to basically create
σw = Max surface pressure = l/a = 4356/375 = 11.616 special products.
MPa
Customer requirements may change and time
f =force on teeth =4356N pressures may continue to mount, but your product
design needs continue the same - disregarding of your
l = length of wheel /Ø = 150Ø task opportunity, you use the effective, easy-to-use,
economical solution that Pro/ENGINEER provides.
b = half width of the contact surface
Modeling
( ( ))
b=[ ]1/2
( )

d 1 & d 2= Ø

v1 & v2 = poisons ratio

E1 & E2 = young’s module

( ( ))
b = [ ]1/2
( )

Figure 3 : Blade
b= [ ]1/2

b = [18.49 ]½

b = [18.49×148.87]½

b = 2752.6 mm Figure 4 : Shaft

Buckling Force

F=

F= buckle force

E = young’s modules = 203GPa.

I = moment of inertia of surface of tool tip =3.65+8

Figure 5 : Blade set 1
L= unsupported length (150-32 =118/2) = 59 mm

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Figure 6 : Assembly

INTRODUCTION TO FEA THE ABOVE IMAGE IS SHOWING MESH MODEL OF

OBJECT, MESHING IS USED TO DECONSTRUCT COMPLEX
FEA consists of a computer model of a material or PROBLEM IN TO NUMBER OF SMALL PROBLEMS USING
design that is stressed and analyzed for specific FINITE ELEMENT METHOD
results. It is used in new product design, and existing
product refinement. A company is able to verify a
proposed design will be able to perform to the client's
specifications prior to manufacturing or construction.
Modifying an existing product or structure is utilized
to qualify the product or structure for a new service
condition. In case of structural failure, FEA may be
used to help determine the design modifications to
meet the new condition.

EXPERIMENTAL RESULTS

Blade material 1: Tool Steel

THE ABOVE IS SHOWING LOAD AND BOUNDARY

CONDITIONS APPLIED ON OBJECTS

THE ABOVE IMAGE IS SHOWING IMPORTED MODEL

FROM CREO-PARAMETRIC USING IGES FORMAT(INITIAL
GRAPHICAL EXCHANGING SPECIFICATION)

THE ABOVE IMAGE IS SHOWING TOTAL DEFORMATION

VALUE

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BLADE MATERIAL 2

THE ABOVE IMAGE IS SHOWING EQUIVALENT STRESS

THE ABOVE IMAGE IS SHOWING TOTAL DEFORMATION
VALUE, IT IS ALSO CALLED AS VONMISSES STRESS WHICH
VALUE
PROVIDES THE AVERAGE VALUE OF DIRECTIONAL AND
PRINCIPLE STRESS USING VONMISSES THEORY OF
FAILURE

FATIGUE ANALYSIS

THE ABOVE IMAGE IS SHOWING EQUIVALENT STRESS

VALUE.

THE ABOVE IMAGE IS SHOWING SAFETY FACTOR BASED ON

STRESSES VERSES NUMBER OF CYCLES(S-N) CURVE

THE ABOVE IMAGE IS SHOWING EQUIVALENT STRAIN

VALUE, IT IS ALSO CALLED AS VONMISSES STRAIN WHICH
PROVIDES THE AVERAGE VALUE OF DIRECTIONAL AND
PRINCIPLE STRAIN USING VONMISSES THEORY OF
FAILURE
THE ABOVE IMAGE IS SHOWING NATURAL FREQUENCY
VALUE AT MODE-1

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FATIGUE ANALYSIS STRUCTURAL

Modified Blade Material 1

THE ABOVE IMAGE IS SHOWING LIFE BASED ON

STRESSES VERSES NUMBER OF CYCLES(S-N) CURVE
THE ABOVE IMAGE IS SHOWING IMPORTED MODEL FROM
CREO-PARAMETRIC USING IGES FORMAT (INITIAL
GRAPHICAL EXCHANGING SPECIFICATION)

THE ABOVE IMAGE IS SHOWING SAFETY FACTOR

BASED ON STRESSES VERSES NUMBER OF
THE ABOVE IMAGE IS SHOWING TOTAL DEFORMATION
CYCLES(S-N) CURVE
VALUE
MODAL

THE ABOVE IMAGE IS SHOWING EQUIVALENT STRESS

VALUE.
THE ABOVE IMAGE IS SHOWING NATURAL FREQUENCY
VALUE AT MODE-5

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STRUCTURAL

FATIGUE ANALYSIS Modified model with Material 2

THE ABOVE IMAGE IS SHOWING TOTAL

DEFORMATION VALUE
THE ABOVE IMAGE IS SHOWING LIFE BASED ON
STRESSES VERSES NUMBER OF CYCLES(S-N) CURVE

THE ABOVE IMAGE IS SHOWING EQUIVALENT STRESS

VALUE, IT IS ALSO CALLED AS VONMISSES STRESS WHICH
PROVIDES THE AVERAGE VALUE OF DIRECTIONAL AND
THE ABOVE IMAGE IS SHOWING SAFETY FACTOR BASED PRINCIPLE STRESS USING VONMISSES THEORY OF
ON STRESSES VERSES NUMBER OF CYCLES(S-N) CURVE FAILURE

MODAL

THE ABOVE IMAGE IS SHOWING EQUIVALENT STRAIN

VALUE, IT IS ALSO CALLED AS VONMISSES STRAIN WHICH
PROVIDES THE AVERAGE VALUE OF DIRECTIONAL AND
THE ABOVE IMAGE IS SHOWING NATURAL FREQUENCY PRINCIPLE STRAIN USING VONMISSES THEORY OF
VALUE AT MODE-5 FAILURE

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Modified - Modified -
Material 1 Material 2
total deformation 0.002997 0.0013622
Stress 8.4519 8.1083
FATIGUE ANALYSIS Strain 8.9331e-5 3.9212e-5
Life 5e9 5e9
safety factor 15 15
alternative stress 84.519 81.083

MODAL Modified - Modified -

Material 1 Material 2
total deformation 153.88 Hz 153.89 Hz
total deformation 165.42 Hz 165.43 Hz
2
total deformation 331.64 Hz 331.64 Hz
3
total deformation 338.58 Hz 338.58 Hz
4
total deformation 397.51 Hz 397.57 Hz
5

THE ABOVE IMAGE IS SHOWING LIFE BASED ON

STRESSES VERSES NUMBER OF CYCLES(S-N) CURVE Modified model with Square Section Material 2

Regular Modified Modified

model Model Model
With With X
Material 2 Square Section
Section Material 2
Material 2
total 0.0013622 0.0013635 0.0013639
deformation
Stress 8.1083 8.0513 8.0382
Strain 3.9212e-5 3.9315e-5 3.934e-5
Life 5e9 5e9 5e9
safety factor 15 15 15
alternative 81.083 80.513 80.382
stress

THE ABOVE IMAGE IS SHOWING SAFETY FACTOR BASED

MODAL Modified Modified
ON STRESSES VERSES NUMBER OF CYCLES(S-N) CURVE
Model With Model With X
Square Section Section
Material 1 Material 2 Material 2 Material 2
total 0.0044395 0.0020231 total deformation 148.41 Hz 148.25 Hz
deformation total deformation 159.72 Hz 159.64 Hz
Stress 11.502 11.043 2
Strain 0.00011981 5.2584e-5 total deformation 320.91 Hz 320.84 Hz
Life 5e9 5e9 3
safety factor 15 15 total deformation 327.5 Hz 327.4 HZ
alternative 115.02 110.43 4
stress total deformation 384.25 Hz 383.52 Hz
5

MODAL Material 1 Material 2

total deformation 153.82 HZ 153.84 Hz Conclusion
total deformation 165.39 HZ 165.4 Hz
2 This project work is done “analysis to optional the
total deformation 331.62 HZ 331.64 Hz design of twin shaft shedder” to provide optional
3
structure, material and design.
total deformation 338.57 Hz 338.57 HZ
4
Initially literature survey and data collection was done
total deformation 397.31 HZ 397.37 Hz
5 on shedders and crushers to understand methodology

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for design, modeling and analysis and also it is used in [6] OPTIMIZATION TECHNIQUE FOR THE VERTICAL
material selection. CRUSHING MACHINE. B.P.Numbi, X.Xia and J.
Zhang, Department of Design and Technology,
Modeling of all the part was done in parametric CAD Loughborough University
software assembly was done then converted as FEM
model to do further analysis work in ansys. [7] DEPARTMENT OF APPLIED MECHANICS
CHALMERS UNIVERSITY OF TECHNOLOGY,
Structural, model, fatigue and harmonic response M.Lindqvist and C.M.Evertsson
analysis was done with two materials titanium or tool
steel to determine stress, strain, deformation, [8] MULTI-OBJECT OPTIMIZATION DESIGN FOR
frequency, life, factory of safety and harmonic values DIFFERENTIAL AND GRADING TOOTHED ROLL
as per the analysis results tool steel is showing better CRUSHER USING GENETIC ALGORITHM. ZHAO La-la,
results for shedder blades the geometrically blade was WANG Zhong-bin and ZANG FENG China University of
modified to reduce stress concentration the new model Mining And Technology,
was analyzed it is showing better then previous model.
[9] JAW CRUSHER PERFORMANCE IN THE GRANITE
In second cause outer structure (box) was modified to QUARY. OLALEYE B M Department Of Mining
improve it’s stability was three models was analyzed. Engineering, Federal University Of Technology, Nigeria.

According to the results “X” shaped outer walls are

showing the optimum values, but in high frequency
box will be the best (metal waste cutting).

This project work concludes that shedder with tool

steel material, will the best option along with blade
corner radius and outer structure with “X” cross AUTHORS
section.
A.Venkata Rathnam,
REFERENCES Research Scholar,
Department of Mechanical Engineering,
[1] DESIGN AND ANALYSIS OF TWIN SHAFT QIS College of Engineering & Technology, Ongole,
SHREADER USING PRO-E AND HYPERWORKS Andhra Pradesh, India.
SOFTWARE First Author : M. Sakthivel Second Author
: G. Rajeshkannan- Asst. Professor Third Author : M.
Naveenkumar- Asst. Professor International Journal of
Advanced Research in Basic Engineering Sciences and U. Hari Babu,
Professor,
Technology (IJARBEST)
Department of Mechanical Engineering,
QIS College of Engineering & Technology, Ongole,
[2] TECHNICAL AND ECONOMIC ANALYSIS OF PRE- Andhra Pradesh, India.
SHREDDING MUNICIPAL SOLID WASTES PRIOR TO
DISPOSAL Garrett C. Fitzgerald Advisor: Professor
Nickolas J. Themelis Department of Earth and
Environmental Engineering Fu Foundation of
Engineering and Applied Science Columbia University

[3] DEVELOPING BULK WEEE POLYMER

SEPARATION AND ANALYSIS TECHNIQUES Authors :
Keith Freegard, Gayle Tan, Sebastien Frisch WEEE
Plastic Separation Technologies

[4] DESIGN AND DEVELOPMENT OF AGRICULTURAL

WASTE SHREDDER MACHINE Mr. M.Sanjay Kumar
and Mr. DR. T.R. Hemanth Kumar Sri Siddhartha
Institute of Technology

[5] DESIGN OF MECHANICAL CRUSHING MACHINE

Mr. Senthil Kannan.N, Mr. Naveen Prasad.D, Nirmal
Mr. Kumar.R, Mr. Premvishnu.R.S Sri Ramakrishna
Engineering College, Tamil Nadu, India

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