The Finite Element Analysis is done by dividing the whole machine to small parts by a process called meshing. Then the small elements which is
technically called Finite Elements is analysed separately using the software and the result obtained by combining the results of the small elements. This methodology is used to obtain more accurate results for the analysis.
5.1 Design for Fabrication and FEA Analysis
The solid model is developed in Solid Works 2010. The model has got a scrap compression box, a plate to compress scrap, two channels to hold the opening door after compressing scrap, a cylinder connected to the compressing plate. The cylinder is bolted to the frame by using M10 Bolts and Nuts.
Fig 5.1 Solid Model of the Scrap Compressing Machine
The model for fabrication is done in Solid Works 2010. The Fig 5.1 shown is the model for fabrication and analysis. The piston is connected to a square plate which goes half way of the compressing chamber. So the scrap is put into the chamber by wearing gloves. Gloves have to be worn as it can prick on bare hands causing injuries.
5.2 Solid Body for FEA Analysis
The solid body shown in Fig 5.2 is used to do the FEA analysis. In this analysis only body is considered and the cylinder is avoided for convenience of analysis.
Fig 5.2 Solid body for FEA
The FEA is done on the solid body by fixing the bottom of the machine. It is evident from the Fig 5.2 that the bottom is fixed and is indicated by green arrows downwards.
Mass = 28.767 kg Volume = 0.00373598 m3 Density = 7700 kg/m3 Weight = 281.917 N 5.3 Meshing for FEA
Fig 5.3 shows the meshing. Triangular meshing is done for the FEA analysis. By doing triangular meshing the solid model is divided into small triangular elements. These triangular elements are then analysed using Solid Works 2010.
Fig 5.3 Triangular meshing is done for doing FEA
The material used for making the model is Alloy Steel. The Yield Strength is 6.20422e+008 N/m2 and Tensile Strength is 7.23826e+008 N/m2. In the model for analysis the face at the bottom is fixed and a Pressure of 15123 N/m2 is applied on the 5 inner walls and 1 compressing plate. The mesh type is solid and mesh quality is taken as High. The total number of nodes is 5488 and total elements are 2750.
5.4 von Mises Stress
The von Mises stress is calculated using Solid Works 2010. The Fig 5.4 shown below shows the von Mises stress distribution.
Fig 5.4 von Mises Stress
The minimum stress is 1.01393 N/m2 on 5126and the maximum stress is 642219 N/m2 on 1766 nodes. von Mises stress analysis helps to find the
maximum stress that the machine can with stand. In other words the maximum allowable stress should be below the maximum von Mises stress.
5.5 Deformation for the Applied Load
The deformation is found using FEA analysis. Minimum displacement is 0 mm on 138 nodes and maximum displacement is 0.00126577 mm on 1772 nodes.
Fig 5.5 Deformation for the Applied Load
Fig 5.5 shows the deformation for the applied load. From the above shown diagram the displacement is maximum at the centre of the plates. The analysis is done by fixing the bottom of the plate and applying a pressure at the faces of the plates.
CHAPTER 6 6.1 Fabrication
The fabrication was done in the Lathe and Welding Workshops. Testing of the machine was done in the Hydraulics Lab. The power pack in the hydraulic lab was utilised for testing the machine. The Fig 7.1 shown below is the perspective, top, side and front view of the machine. The dimensions of different parts are marked in the figure and all dimensions are in centimetre.
Fig 6.1 Detailed Drawings of the Machine
All the metal parts were procured by gas cutting. The channel was made by milling operation. The box for compressing scrap was made by welding in the workshop. The design was done in such a way that the machine can be dismantled if required to do any further adjustments or maintenance.
The model for fabrication is done in Solid Works 2010. The Fig 6.1 shown is the model for fabrication. It has got a hydraulic cylinder with a piston. The piston is connected to a square plate which goes half way of the compressing chamber. So the scrap is put into the chamber by wearing gloves. Gloves have to be worn as it can prick on bare hands causing injuries.
6.2 Testing of the fabricated Scrap Compressing Machine
The Fig 6.2 below shows the fabricated Scrap Compressing Machine and its testing in the Hydraulics Lab. The Scrap Materials are collected from the CNC Lathe and put it into the scrap compression chamber. Then hydraulics is applied to compress the scrap. The pressure gauge was showing a reading of 50-55 Kg/cm2 while compressing the scrap. The scrap is put in the machine and compressed by turning the leaver of DC Valve.
Fig 6.2 Testing Scrap Compressing Machine
After compressing more and more scrap is put in the chamber and compressed to form the block of compressed scrap. At last when the chamber is
filled with the scrap the end opening is opened by lifting the plate through the channels and the compression is further given to push out the scrap out of the chamber.
The compressed scrap is shown in Fig 6.3. The initial volume of the block was 21202 cm3 and after compressing the scrap it will become 5832 cm3. The volume of the compressed scrap is reduced by the ratio of 3:1.
Fig 6.3 The Compressed Scrap
Two bucket of the size shown in the figure is compressed to form the scrap block which is in my hands.
CHAPTER 5 Conclusion
The Scrap Compressing Machine for small scale industries is developed, designed, fabricated and tested. The costing of the machine is calculated and the break even period is determined. It was found that the break even period of the machine is 11 months. The machine design and FEA analysis is done in Solid Works 2010. A fatigue analysis and analysis for welded joint is also calculated.
And it was deduced that the machine will sustain the load applied. The scrap is compressed and the volume of the scrap will be compressed by the ratio of The detailed drawings and pictures of the Scrap Compressing Machine are documented. The initial volume of the block was 21202 cm3 and after
compressing the scrap it will become 5832 cm3. The volume of the compressed scrap is reduced by the ratio of 3:1. This is for aluminium scrap.
REFERENCES
[1] Liu Jianxiong, Peng Juntao, Yang Bangcheng, Hou Jie, The Research on Shredding Models of Light Metal Scrap of End-of-life Vehicles and Household Appliances, IERI Procedia, Vol.1, 2012, Pages 146-154.
[2] Manufacturing Process for Engineering Materials, 5th Edition, Kalpakjian, Schmid
[3] S Jalaludeen, “Design of Machine Elements”, Machine Design -1, 4.142, 1.42, 1.46, 3.15.
[4] S. Darius Gnanaraj, Scrap compression machines- overview, National Seminar on Ergonomics for Enhanced Productivity, Tamilnadu Agricultural University, Madurai, India, (Feb. 18th & 19th 2013)
[5] Technical Training Manual on Hydraulics,TORO University, USA.
[6] Technical Training Manual on Weld Joints and Weld Types, Chapter 6, The Goodheart-Willcox Co., Inc.
[7] information on http://www.industrysearch.com.au/Scrap-Metal-Baling-Press- SMB- F125/p/55463
[8] information on http://www. hydraulicspneumatics.com [9] information on http://www.iqsdirectory.com/balers/
[10] information on www.freepatentsonline.com
[11] information on http://irsme.nic.in/files/ScrapMgt-Akhilesh.pdf [12]
information on http://www.santecindia.com
[13] information on www3.nd.edu/~manufact/MPEM%20pdf_files/Ch12.pdf
Name
DESIGN OF A SCRAP COMPRESSING MACHINE FOR SMALL SCALE INDUSTRIES
PG Cert, PRODUCT DESIGN, INNOVATION AND MANAGEMENT, MIDDLESEX UNIVERSITY, LONDON, 2007
Cert, ENTERPRISE SKILL, JUDGE BUSINESS SCHOOL, CAMBRIDGE, U.K NATIONAL SEMINAR ON “ERGONOMICS FOR ENHANCED
PRODUCTIVITY” FEB 18TH AND 19TH
ERGONOMIC DESIGN OF A SCRAP COMPACTOR, ICE 2013, 2ND INTERNATIONAL CONFERENCE ON ERGONOMICS, UNIVERSITY OF MALAYA (PAPER ALREADY SUBMITTED)
NIL
SolidWorks 2013, Ansys 14.5,Pro-E, Gambit &Fluent, R-STUDIO INDUSTRIAL ENGINEER, ORIENT FASHIONS PVT LTD, 2004-2005 OPERATIONS MANAGER, YMCA LONDON, U.K. 2005-2008
7-5-2013 Signature