Design of Mechanical Crushing Machine

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 03 Issue: 01 | Jan-2016 www.irjet.net p-ISSN: 2395-0072
© 2016, IRJET | Impact Factor value: 4.45 | ISO 9001:2008 Certified Journal | Page 921
DESIGN OF MECHANICAL CRUSHING MACHINE
Senthil Kannan.N1, Naveen Prasad.D2, Nirmal Kumar.R2, Premvishnu.R.S2
1 Assistant Professor, Dept of Mechanical Engineering, Sri Ramakrishna Engineering College, Tamil Nadu, India
2 U.G. Student, Dept of Mechanical Engineering, Sri Ramakrishna Engineering College, Tamil Nadu, India
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Abstract - The paper is about fabrication of
mechanical crusher which would help to crush the used
juice cans, paint cans and punched sheet metal waste.
This paper aims to design a crusher that could be
installed anywhere and would aid crush of used wastes.
This paper involves the process of designing the crusher
considering forces required for crushing and ergonomic
factor that an operator needs. The design of this
machine is such that it would require optimum load to
crush metals and will not strain the user or operator.
After the completion of design process, it is
manufactured and transformed into a machine that
would help in waste management. The crushing of used
cans will also ensure that the cans are not used beyond
the self-life of the metals. Therefore this paper will
prove to be a useful asset in many ways. We have
designed the crushing machine using Modelling
software’s. The crusher is designed based in the simple
principle or a mechanism which is Crank and Slotted
Lever Mechanism where the rotary motion from the
motor is converted into reciprocating motion by the
crank which is in-turn connected to the piston that
crushes materials. The Designed components were then
assembled and analyzed using an analysis software
and the required dimensions of the crusher for the
optimum performance have been found. These data’s
were then transformed into a real time model by
manufacturing it. The designed crusher was then
checked and the crusher effectively crushed all the
components with ease and with reduced human effort.
Key Words: crusher; crank and slotted lever mechanism;
reciprocating motion
1. 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 transporting the
wastes to the recycling plants, wherein a huge amount of
effort, time and money needs to be put in for transporting
the wastes which are clustered and are not in uniform
shape or size. The waste materials needs to be made into a
uniform shape for easy and effective transportation. This
paper aims in producing a mechanical crusher which
would be a helping hand for waste management. This
crusher can be used for crushing sheet metal wastes, paint
cans, cool drink cans, machining scraps for reducing the
space occupied by these while carrying it to the recycling
plants. Cans and tins 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
baled up according to the size of the crushing bin. The
uniform size and shape of the materials can be obtained by
providing a bin onto which the material is to be crushed.
The crusher is designed to operate by both mechanical
and electrical means. This crusher is designed in such a
way that it is simple to construct and would require
minimum effort for operating in both mechanical and
electrical types of operation.
2. WORKING PRINCIPLE
The crusher is designed to operate on a crank and slotted
lever mechanism and the power for the electrical
operation of the crusher is taken from an electrical motor.
It is designed to use a 3 phase induction motor for the
electrical operation of the crusher as the power required
for crushing the sheet metal is high as compared to that of
a normal paint or cool drink can. The distance between the
motor and the larger pulley commonly called as the Centre
distance plays a major role in the fabrication of the
crusher as this distance is the critical parameter for
maintaining the crushing force [1]. The Centre distance is
fixed in such a way that the torque is more and the speed
of the rotation is less. By increasing the Centre distance
higher force can be obtained and motor running speed can
be reduced. The basic structure or frame of the crusher is
to be built using a flat rod of mild steel material. The

power transmission from the motor is by means of a
pulley and the pulley is to be attached to a main shaft. The
main shaft is supported at the Centre by means of ball
bearings as the distance between the pulley and the crank
is more. This bearings eases the power transmission and
reduces the transmission losses [2]. These bearings also
reduce the friction on the rotating shaft and also prevents
bending or torsional stresses acting on the horizontal rod.
The main shaft houses the crank plate. The crank plate
made up of mild steel in circular shape is a solid thick plate
onto which the piston rod is to be connected. This is the
one which plays a key role in converting the rotating
motion of the motor to the required reciprocating or
oscillatory motion. If the diameter of the crank plate is
small, then the speed of reciprocating motion will be high
and this reduces the crushing force. If the diameter of the
crank plate is high, then the piston reciprocates slowly and
the crushing force exerted by the piston will be really high
thus damaging the bin which is at the end of the piston.
Therefore, optimum diameter of the crank plate should be
maintained for the effective operation [3]. Three holes are
provided in the crank plate to connect the piston rod
according to the material needed to be crushed. Their
distances are arranged in such a way that the crushing
force and the speed of operation can be varied to some
extent for crushing different materials [4]. The main shaft
is a circular rod made up of mild steel and round thick
plate is used as a crank
Which is in turn attached to the piston rod and the piston.
A rectangular bin of mild steel is constructed to withstand
the high crushing force that the piston exerts on the bin
while crushing the waste materials. The bin shape,
material and design of the bin varies according to the
crushing material. This is so because the crushing force
required for crushing the tin is not same as that of the
force required for crushing a sheet metal waste or a metal
scrap. The material is put into the crusher using a hopper
and the bottom plate of the bin can be removed as to the
crushed waste can be taken from the bottom part. The
removed waste is in the shape of the bin and holds
together as a single solid model and is easy to transport.
3. OPERATING MECHANISM
This crusher works on the simple mechanism called crank
and slotted lever mechanism. When the motor is excited
using a power source (i.e.3-phase power supply in this
case) the shaft starts to rotate which in turn 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 crush the material and as the
piston reciprocates inside the bin onto which the materials
are placed or fall one by one with the help of a hopper gets
crushed and acquires the shape of the bin [6]. This
crushed material can now be removed from the bin from
the bottom part by removing the base plate of the bin and
can be transported just as it is to the recycling plants.
4. CRUSHERS
Nowadays, waste management is one of the areas
which is gaining importance day by day. The amount of
waste coming is in a tremendous quantity. Aluminium
cans and Tin cans are the important products which are
being recycled on an increasing scale. For carrying out this
process mechanical crushers are used. For recycling of
these cans, large crushers are being used in industries,
which is not suitable for small scale industries as the
machines cost high. In order to crush the cans in a less
time, a can crusher machine using crank and slotted lever
mechanism having high crushing ability can be employed.
A mechanical crusher machine is used for crushing
aluminium cans and punched sheet metal wastes for
recycling purpose and also for easy storage and
transportation. The crank and slotted lever mechanism
converts the rotating motion into reciprocating motion,
this is the principle which is used in the mechanical
crusher.
4. METHODOLOGY
4.1 Existing Methods
The existing crushers are heavy ones and these crushers
are excessively used for crushing materials at big
industries and manufacturing plants for crushing cars,
stones, metal components, etc., Moreover, these crushers
are hydraulically and pneumatically operated and is
feasible if very high amount of crushing forces are
required for crushing a material [8]. The operating costs of
these crushers are very high as it requires continuous
power, continuous maintenance as this involves hydraulic
fluid or compressors kits, etc., these type of high end
crushers are not necessary for small recycling plants and
is not affordable to many people. It requires proper
maintenance as the hydraulic fluid needs to be changed
constantly on time basis. It also requires skilled labor for
operation [9].

Chart-1: Work Methodology
4.2 Proposed Method
The crusher that is designed is done in such a way that
even a layman can operate it. The current crusher uses
crank and slotted lever mechanism to crush the materials.
The construction is simple and manufacturing of this does
not cause much pain. The manufacturing cost as well as
the maintenance cost is very less as compared to that of
hydraulic machines. This crusher can crush the waste
effectively and also the operating time is very less as
compared to the existing ones. This crusher would best
suit the small recycling plants and small industries and
also shopping malls for crushing small and simple
materials like paint cans, soda cans, aluminium tins,
machining scrap, sheet metal waste, etc.,
6. LITERATURE REVIEW
1) B.P.Numbi, X.Xia and J. Zhang, have presented an
optimization technique for the vertical crushing machine.
The paper presents the optimal control model to improve
the operation efficiency of a vertical shaft impact crushing
machine. They have proposed optimum methods to reduce
the power consumption by varying the conveyor feed flow
rate, the vertical shaft impact crusher rotor feed rate and
the bi-flow or cascade flow rate.
2) Department of Design and Technology,
Loughborough University, has presented a paper
emphasizing the need for recycling the wastes particularly
the metal can wastes. The paper insists that the
requirement for environment accountability has become a
feature of consideration for the engineers, especially for
mechanical engineers. The various design methodologies
have been discussed in the paper for the construction of a
can crusher which would be helpful in waste management.
3) M.Lindqvist and C.M.Evertsson, Department of
Applied Mechanics Chalmers University Of Technology,
Sweden have presented a paper to develop a wear model
for the cone crushers which are used to crush the rocks
minerals which are in the form of ores in mines.
Disagreements between predicted and measured
geometry and several effects were suggested to explain
the discrepancy in the model. The model is of complex
construction and it has some of the real time shortcomings
which reduces the efficiency of the machine drastically.
The various drawbacks have been studied and the
measurements have been done to predict the efficiency.
4) ZHAO La-la, WANG Zhong-bin and ZANG FENG of
China University of Mining And Technology, have
presented a paper on the Multi-object Optimization design
for differential and grading toothed roll crusher using
genetic algorithm. The crusher blends the efficiencies of
toothed roll crusher and also the jaw crusher to possess
great crushing ability and high breaking efficiency [10].
Crank rocker mechanism forms the basis of the machine.
Thus the construction of the machine becomes
complicated and as a result the cost of the machine
increases.
5) OLALEYE B M Department Of Mining Engineering,
Federal University Of Technology, Nigeria, has proposed a
paper on Jaw Crusher performance in the granite
quary.The paper determines the Effect of Rock Strength on
Crushing Time and Grain Size Distribution of the rocks.
Investigation was conducted with five sample rocks and
the performance and drawbacks were spotted out. Various
tests have been performed and the results have been
tabulated and plotted in the form of graphs.
7. WORKING PRINCIPLE
The machine has been constructed in such a way that it
can be operated by both electrical and mechanical means.
The drive unit consists of an electrical motor of 0.5Hp. The
motor is fitted with a smaller pulley of 0.05m diameter.
Performance Objectives
Studying the process
Data from Various sources
Drawing the part model by any
Design Software
DDesign
Assembling the Part models using
any Design Software
Analyze the Results
Manufacturing the Crusher as
per the required dimensions
Fixing the dimensions based on
calculations
Calculating the required
dimensions to achieve the
required crushing force
Assemble the components

The power from it is transferred to the larger pulley of
0.41m diameter by means of a V-belt drive. The larger
pulley drives the main shaft which houses the crank. The
main shaft is supported on the machine frame by means of
two ball bearings housed inside Plummer blocks to
prevent vibrations. The presence of bearing also reduces
friction over the shaft. The crank is rigidly fixed to the
shaft. The connecting rod is fixed to the crank by means of
temporary fasteners to provide rotational motion to it. The
connecting rod is fastened to the piston rod which is in
turn connected to the piston. The piston reciprocates
inside a bin in which the wastes are placed it also acts as a
guide way for the piston. The power from motor in the
form of rotation is converted to reciprocating motion by
means of crank and slotted lever mechanism. Thus the
cans and other wastes are crushed efficiently.
8. CAD MODEL
Fig –1: Front Assembled View
Fig – 2 : Side Assembled View
9. DESIGN CALCULATION
Crank diameter = 20cm
Motor power = ¾ HP
= 0.566025 kW
Length of connecting rod = 20 cm
Speed of the Motor = 1440 rpm
Mass of ram = 2 Kg
Force exerted (F) = m*g
= 19.62 N
Motor speed is transmitted to crank, with the help of V-
belt drive.
N 1/T
Diameter of Pulley 1 = 6.35 cm (d)
Speed = 1440 rpm (N1)
Diameter of Pulley 2 = 40.64 cm (D)
Speed = ? rpm (N2)
D/d = N1/N2
N2 = 225 rpm
Centre distance of pulley = 2 (D + d)
C = 94 cm
P = (2πNT)/60
T = 0.94 Nm
S = V = (πDN1)/60000
= 0.47 m/s
Arc of contact
= 180o – (D – d)/C * 60o
= 179o6o
= 2.78 radian
We Know That,
(T1 – mv2)/(T2 – mv2) = e((µα) / sin θ/2)
m = 0.106
v = 0.47 m/s

Assume, µ = 0.9
θ = 40o
α = 2.78 radian
But,
P = (T1 – T2) V
5.66 = (T1 – T2) 0.47
T2 = 1.213 N
T1 = 13.21 N
Stress σ = T1 / Sectional Area
From PSG Design Data Book,
A = 80 mm2
= 13.21 / 80
σ = 0.165 N/mm2
10. PROPOSED COST OF THE MACHINE
TABLE – 1 : Cost Table
S.NO MATERIAL COST
1 Mild steel angle rod RS.300
2 Circular rods (25mm dia. , 13mm dia) RS.320
3 Bearings 2Nos RS. 260
4 Circular and square plates RS. 280
5 Pulleys RS. 800
6 Belt RS. 200
7 Welding Cost RS.2000
8 Total Cost RS.4160
6 Belt RS. 200
7 Welding cost RS.2000
8 Total cost RS.4160
11. FUTURE SCOPE
The future scope of the paper is to upgrade the machine
with lot more facilities. That is to equip the machine with
automatic loading facility, sensors and microcontrollers to
detect the material input to switch on and off the machine
automatically in order to reduce the power consumption.
12. RESULTS AND DISCUSSION
The crushing machine was successfully fabricated and the
machine was tested. The machine crushed multiple cans
simultaneously with ease both during electrical as well as
during mechanical modes of operation. While crushing the
cans manually, the cans got crushed with minimal human
effort and reduced the fatigue factor of the worker.
13. CONCLUSION
The crusher is constructed in such a way that even a
layman can operate it without much effort. It is made
efficient and the cost of production of this crusher is very
less. The crusher has been designed accordingly keeping
in mind about the minimum power requirements and
minimum effort to the operator. This crusher upon
fabrication would serve its purpose the small scale
recycling plants and does not require power for operation
and can also be operated manually without much physical
effort.
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Design of Mechanical Crushing Machine

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