Scrap chip compressing machine

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DESIGN OF A SCRAP COMPRESSING MACHINE

FOR SMALL SCALE INDUSTRIES

a project report Submitted by

BOBBY P PAUL

(REG. NO: PR11ME1009)

in partial fulfilment for the award of the degree of

MASTER OF TECHNOLOGY

IN

MECHANICAL ENGINEERING (DESIGN)

Under the guidance of

Dr. S DARIUS GNANARAJ

Dean Research

DEPARTMENT OF MECHANICAL ENGINEERING

SCHOOL OF MECHANICAL SCIENCES

KARUNYA UNIVERSITY

(Karunya Institute of Technology and Sciences)

(Declared as Deemed-to-be-under Sec-3 of the UGC Act, 1956) Karunya Nagar, Coimbatore - 641 114, INDIA.

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BONAFIDE CERTIFICATE

This is to certify that the project report entitled, “DESIGN OF A SCRAP

COMPRESSING MACHINE FOR SMALL SCALE INDUSTRIES” is a

bonafide record of work of BOBBY P PAUL (PR11ME1009) who carried

out the project work under my supervision during the academic year

2012-2013.

SIGNATURE

DR. DARIUSGNANARAJ

Professor SUPERVISOR DEAN RESEARCH KARUNYA UNIVERSITY

SIGNATURE

Dr. M. SEKAR

Professor

HEAD OF THE DEPARTMENT Department of Mechanical Engineering

Submitted for the (Full Semester Project) Viva Voce held on………

………...

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ACKNOWLEDGEMENT

At the outset, I express my gratitude to the ALMIGHTY GOD who has been with me during each and every step that I have taken towards the completion of this project.

I thank our beloved founder late Dr. D.G.S. DHINAKARAN, Ph.D., and our Honorable Chancellor Dr. PAUL DHINAKARAN, Ph.D., for providing me the educative infrastructure and learning ambience, which motivated me to a great extent. I wish to thank the Management of Karunya University and our Vice Chancellor, Dr. E.J. JAMES, Ph.D., and Registrar, Dr. C. JOSEPH KENNADY, Ph.D., for extending all facilities.

I would like to place my heart-felt thanks and gratitude to Dr. T. V. CHRISTY, M.E, Ph.D., Director, School of Mechanical Sciences for his encouragement and guidance. I extend my thanks to Dr. M. SEKAR, M.E, Ph.D., Head of the Department, School of Mechanical Science.

I thank with deep sense of gratitude to my guide Dr. S. DARIUS GNANARAJ, M.E, Ph.D., Dean Research, for his exhilarating supervision, timely suggestion and guidance during all phase of this work.

I thank the co-ordination and help of my external guide Mr. J. CHANDRAN and Mr. JAYSEELAN, Vishal Precision Products Pvt Ltd, Coimbatore, Tamilnadu for their constant support, helping hand and encouragement in the project.

I would take this opportunity to thank our Class Advisor Mr. WALTER, M.Tech, and Assistant Professor who had been always there for us. Also, I would like to thank all the teaching faculty members and supporting Staff of our department for co-operating and arranging the necessary facilities.

I would like to thank Dean Research for granting me necessary funding from KSTPG for the project execution. I would like to convey gratitude to my PARENTS whose prayers and blessing where always there with me.

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ABSTRACT

Scrap is one of the most ignored wastes in any Industry. Scarcity and rising of commodity prices increase the importance of scrap recycling. There are many advantages in compressing scrap. The storage space will be saved thus either the size of the storage room can be reduced or more scrap can be stored in the space available Transportation cost will be reduced as more amount of scrap can be transported at a time. Handling of the scrap will become easier as they are made into blocks. So a study was conducted in a small scale industry which deals with Jigs, Fixtures and manufactures many small machines like heavy duty printers etc. Required data for the design of the scrap compressor, for the hydraulic circuit, the compression ratio, force required for compression are collected from the Literature Survey. The current practice of scrap removal and storage in the industry is shown using photographs. The calculations for arriving at the force required for compaction is shown. The hydraulic circuit diagram and testing of a similar circuit in pneumatic test bench are explained. Cost of the prototype and the break even period are discussed. Finite element analysis of the solid model is done in Solid Works 2010. The deflection of the plate when a pressure is applied is found. The design calculations for welding and the fatigue analysis considering factor of safety is also performed. Fabrication and testing of the machine is executed in the Work Shop and Hydraulics Lab.

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LIST OF FIGURES

Figure No. Description Page No.

3.1 Scrap lying on shop floor 10

3.2 Magnet for removing Scraps 11

3.3 Scrap Storage 11

3.4 Tray for carrying Scrap 12

4.1 Picture that demonstrates Pascal’s Law 13

4.2 Diagram for Explaining Hydraulic Leverage 14

4.3 Basic Hydraulic System 15

4.4 Reservoir 15

4.5 Pump 16

4.6 Control Valve 17

4.7 Hydraulic Circuit for Scrap Compressing Machine 20

4.8 Testing the Circuit in Pneumatic Lab 22

4.9 Pneumatic Circuit 22

4.10 Different types of welded joints 23

4.11 Fillet Weld 23

4.12 Shielded Metal Arc Welding 24

4.13 Initial Concept of the Scrap Compressing Machine 27 5.1 Solid Model of the Scrap Compressing Machine 29

5.2 Solid body for FEA 30

5.3 The triangular meshing is done for doing FEA 31

5.4 von Mises Stress 31

5.5 The Deformation for Applied Load 32

6.1 Detailed Drawing of the Machine 33

6.2 Testing of Scrap Compressing Machine 34

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LIST OF NOMENCLATURE

ABBREVIATIONS ACRONYMS CNC Computer Numeric Control CMM Coordinate Measuring Machine

ELV End-of-Life Vehicle LMS Light Metal Scrap

ELHA End of Life Vehicles and House Hold Appliances

SMB Scrap Metal Baling Press DCV Direction Control Valve FCV Flow Control Valve PRV Pressure Relief Valve INR Indian Rupees

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CHAPTER 1 INTRODUCTION

1.1 About the Company

The company in which the study was conducted started in the year 1986. They are successfully catering to Engineering industries for over a decade now. They have technical expertise, strict quality control, competitive pricing and prompt delivery can help other companies to reduce delivery time and increase its productivity. The company makes Standard Mould Bases, Manufactures Precision Components, and Assembles Sub-Assemblies for Printing, Paper, Textile, Aero & Oil type of Machineries Worldwide. The company has all the required facilities for machining and inspection, equipped With CNC Machining Centres & Other Machineries, CMM & Height Master. They manufacture as per Customer Drawings & Specifications and has qualified personnel to meet any technical demand. This paper reports the ergonomic design of a scrap compressor to compress the scrap material coming out from small machineries like lathes, drilling machines, milling machines etc. The project is proposed by the industry because the scraps coming out from the machine has to be removed every week as the space allocated will become full in a week. It also consumes lot of manpower to do the cleaning.

The management of scrap is one of the most avoided and difficult part in an industry. The scrap from lathe, drilling machine and milling machine lie on the shop floor makes the work difficult. Also the scrap takes more space than required. Manual handling of scrap material poses problem in industries. More volume and weight can be transported if the scrap material is compressed. This method also helps in selling scraps and recycling economically.

For compressing the scrap, different technologies can be used. Mechanical, Hydraulics or Pneumatic systems can be developed to compress the scrap. Hydraulic technology is selected as it can deliver more force on the scrap to compress. Pictures of the scraps on the floor and the dumping yard were

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recorded. A general study was conducted to find the time taken to remove the scrap and the cost behind the removal. A general question and answer session was conducted to take feedback from the employees and the management about the current scrap management.

This project is the approach of designing the scrap compressor and to develop a concept by incorporating Ergonomic principles. The concept developed is further developed in a detailed way to make the machine to do the job efficiently and effectively. A detailed costing is done to find the cost of the machine. These details will help small scale industries to install a scrap compressor. This project is important in industrial point of view because it saves cost by reducing required man power for scrap removal, and it makes the scrap handling and transportation easier.

At the moment there are no scrap bailers specifically made for compressing scraps coming out from lathes, drilling and milling machines. There are many large size scrap bailers available in the market for compressing scraps. The idea behind doing this project is to take a pump line out from any hydraulic packs available in the industry and connect it to the machine made and scraps can be compressed.

1.2 Common Scrap Bailers Available in the Market

The detailed description of some scrap bailers readily available in the market are given below.

1.2.1. Triple Compression Scrap Bailing Press

Triple compression balers are used for reducing three dimensions of the scrap material by using hydraulic force from three different angles. The two horizontal cylinders are arranged at right angles to each other. Vertical reduction generally takes place by hydraulic pressure on the lid cylinder. One of the horizontal cylinders presses the scrap against the ejection door of the baler. This door is raised hydraulically after baling is complete. The bundle is then removed from the chamber by horizontal cylinder.

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The feeding of the scrap is done with Small balers. Metal may be fed into the press box or chamber manually or by means of a loading hopper. A fairly large bin is kept on the side or front of the boiler. The advantage of hopper is that they can be filled during the baling cycle, which may take a minute or more. The hopper also adds to safety of the operator as manual filing involves greater risk.

1.2.2 Double Compression Scrap Bailing Press

Scrap balers are used for reducing the scrap materials in two dimensions by using hydraulic force from two different angles. The bale density is slightly less than triple compression baler. The balers have one cylinder fixed in horizontal position. Vertical reduction usually takes place by hydraulic pressure on the lid cylinder. The horizontal cylinder presses the scrap against the ejection door of the baler. This door can be raised or opened hydraulically after the process of baling is complete. The scrap bundle is then removed from the chamber by horizontal cylinder.

1.2.3 Triple Compression Scrap Bailing Press

Horizontal type single compression scrap machines are used for reducing only single dimension of the metallic scrap. It uses the compression force generated by the hydraulic cylinder. The exit doors and lid can be opened manually by the operator. Our single compression scrap balers can be customized as per the specific requirements of the clients.

1.3 Aim

To design a scrap compressing machine to compress the scrap material comes out from small machineries like lathes, drilling machines etc.

1.4 Scope of the Project

 Scraps can be compressed to create small blocks.  Space can be saved in the industry.

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 More scrap material can be transported.  Scrap recycling will become easier.

 The efficiency of the company can be measured.

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CHAPTER 2 LITERATURE SURVEY

2.1 The Research on Shredding Models of Light Metal Scrap of End-of-life Vehicles [1]

According to the Authors (Liu Jianxiong et al, 2012) the paper titled “The Research on Shredding Models of Light Metal Scrap of End-of-life Vehicles and Household Appliances” A detailed description of design, development and testing of the machine is illustrated. The objective of the research is to find solutions to reuse of end-of-life vehicles and household appliances (ELV and ELHA). On the basis of the working principle of shredders, the experimental shredding installation for Light Metal Scrap (LMS) was constructed. With the help of a photoelectrical microscope with 50 times magnifying power, the feature of LMS surface appearance, including surface scratches, was acquired before and after testing, respectively. Through analyses of experimental results, some general conclusions were reached which those small cracks, in the surface of LMS that are continually struck by Impacting tools, formed during manufacture, originate very severe concentrations of stress and strain; the concentrations of stress and strain induce stability loss, extension, connection, perforation of small cracks on the surface of LMS; after that single fragments (200mm×200mm) are torn off from the large plate-shaped of LMS. Under the guidance of analytical Study, damaging and shredding modes of LMS are investigated by using experiments. The successful investigation of shredding model of ELV and ELHA will build the models of their shredding process.

After the experimental and analytical investigation of the starting process of LMS, the fellow results were achieved. First point: There are many scratches and rust stains in the specimen surface, for the initial processing and open-air depositing. In fact, these surface defects or cracks are the important reason to bring the LMS to start. In the starting test, the global bending deformation makes specimen to give rise to severe concentrations of stress and strain at original

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surface crack tip. Third point: The impact of swing hammer tip brings specimen to local tiny sunken deformation that exacerbates the original defects and crack on surface of LMS stability loss, propagation, extension, connection, perforation. Fourth point: The single fragments (200mm×200mm) are torn off from the large plate-shaped of LMS eventually by controlling the expansive direction of the crack-tips, and the purpose of recovering metal scrap is achieved. According to TORO University technical training manual on Hydraulics explains all about hydraulics and hydraulic circuits. The required circuit of the project is developed with the help of this book.

2.2 Scrap compression machines- overview [4]

According to the Author (S. Darius Gnanaraj 2013) the paper titled “Scrap compression machines- overview” explains the scope of making a scrap Compressing Machine for small scale industries. It describes all about the different scrap compressors available and its relevance in the industry for better safety, productivity and ergonomics. It also highlights about the accumulation of scrap in the industry and the problems involved in disposal of the scrap. Ideas for designing a scrap compressor using ergonomic principles at a lower cost are also illustrated in this paper. It also considers the best postures of the people collecting the scrap.

2.3 Scrap Metal Baling Press (SMB-F125) Supplied by Enrapt Machine Co., Ltd [7]

According to Electronic source Scrap Metal Baling Press (SMB-F125) Supplied by Enrapt Machine Co., Ltd gives the specification for scrap room and the maximum force that can be applied for that scrap room. According to Electronic source Hydraulics and Pneumatics gives the picture of the Hydraulic Circuit. According to Electronic source IQS Directory gives the details on scrap compression ratio.

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2.4 Scrap Shear Machine with Adjustable Throat [10]

According to the Author (P Gene Ashley 1979) the US patent “Scrap Shear Machine with Adjustable Throat” A scrap shear machine comprises of a compression box, and an indexing ram and a ram head mounted thereon for incrementally advancing the log into the throat of the shear, whereby increments of the log are sheared off. Arrangements are provided for adjusting the width of the ram head in accordance with the width of the compression box and shear throat, whereby the maximum dimension of the sheared scrap can be controllably adjusted in one pass through the machine.

This invention relates to scrap shear machines and, more particularly, to a novel and highly-effective scrap shear machine wherein the machine can be controllably adjusted in one pass through the machine. Scrap metal is divided into ferrous and nonferrous categories and within each category is sold by dimension. For example scrap having maximum dimension of three feet, four feet or five feet is sold by the scrap processor, depending on the requirements of the smelter or other customer for the scrap metal. If the customer will accept scrap having a maximum dimension of five feet, the scrap processor will wish to sell five foot scrap than smaller scrap.

2.5 Scrap Material Shredding and Compressing Apparatus and System [10]

According to the author (James L.Lewis, Jr et al, 2008) “Scrap Material Shredding and Compressing Apparatus and System” the US patent says, A scrap material recycling apparatus includes a feeder, a shredder and a separator, the feeder and the shredder mutually coupled, and the shredder and separator mutually coupled. The feeder includes a means for advancing the scrap material to the shredder. The shredder includes a rotor having a plurality of cutting means, the rotor mechanically rotated to reduce the scrap material. The separator separates the reduced scrap material by fractional composition. The recycling apparatus may be part of a system further incorporating additional components, such as conveyors and/or dust extraction devices. The recycling apparatus may

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be further adapted so as to be a transportable system, thereby allowing such system to be relocated at or near scrap material stockpile locations.

In one aspect of the disclosed embodiments, a scrap material recycling apparatus comprises a feeder, a shredder and a separator, the feeder and the shredder mutually coupled and the shredder and separator mutually coupled. The feeder comprises a means of compressing a quality of scrap material and means for advancing the scrap material to the shredder. The shredder comprises a rotor having a plurality of cutting means, such as teeth, knives, or hammers, wherein the rotor mechanically rotates to reduce the scrap material. The separator sorts the reduced scrap material by fractional composition.

2.6 Creation of Facilities for effective management of scrap at railway units[11]

According to the Electronic source “Creation of Facilities for effective management of scrap at railway units” says, all railway units involved in the maintenance of infrastructure generate scrap. This scrap can be classified into the following categories

 Recyclable ferrous metal  Recyclable non-ferrous metal  Recyclable plastic / polymer  Recyclable glass

 Non-recyclable rubbish

The scrap generation and inadequate system of removal results in creation of stockpiles of unwanted material. One the major factors which hinders the rapid removal of scrap is the cost of transportation which is the same for a good or bad material. Compounding the problem is the fact that scrap is never homogenous, which causes increase in bulk making the cost of transport even greater

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 The cost of transport needs to be reduced

 The scrap should be processed partially to create a more desirable, easily transportable and conveniently recyclable product.

 The non-recyclable rubbish needs to be disposed of at the railway premises (this is also the requirement of the law under EPA-86) this is possible by incinerating the same and disposing of resulting soot in landfills as permitted.

For the recyclable material processing facilities need to be created at the convenient locations (old workshops in the vicinity may be ideal) for initial processing. This will include

 Compressors / pulverisers

 Material sorter / washing systems  Melting and casting process systems

This will be required for each type of recyclable material. A desirable end product would be billets of the raw material, which can be then transported easily for further processing. Most of the old mechanical workshops of the Indian Railways have foundries. These can be converted to form recycling facilities for scrap management.

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CHAPTER 3

CURRENT PRACTICE OF SCRAP REMOVAL AND STORAGE IN VISHAL PRECISION PRODUCTS PVT LTD

3.1Current Practice of Scrap Removal and Storage

The Fig 3.1 shows the scrap lying on the floor of the industry where which the study was conducted to do the design. As we can see in the picture the scrap remains scattered and it’s all over the floor not just in the tray where the scrap should be lying.

Fig 3.1 Scrap lying on shop floor

The scrap lying on the floor is cleaned using the magnet shown below in Fig. 3.2. But this is not done very frequently. The cleaning is done only when the worker cannot work on the shop floor. So as we can see the scrap gets piled up on the shop floor which causes significant difficulty for the worker to perform their job. The scrap pieces could get pricked in the legs of the worker. This can cause serious health and safety issue in the working environment. The Fig 3.2 shows the ergonomically designed magnetic collector to collect the scraps from the shop floor. This is how they remove the scraps in a small scale way. That is,

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while working if some scraps come on the floor where the worker is standing they remove the scrap using the above shown scrap collector.

Fig 3.2 Magnet for removing Scraps

The magnet is kept on an iron tray. Then the tray gets magnetised. The magnetised tray is rolled over the scraps so that the scraps will get stick to the bottom of the tray. Then when the scrap needs to be released then the magnet is flipped up wards so that the iron tray will get demagnetised and the scrap will be released. Scraps from different machines collected in a container.

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The Fig. 3.3 shows the room where which the scrap is stored. The scrap is stored and retrieved from the room in an unorganized manner. This causes extra effort and man power in both the scrap storage and removal.

Fig 3.4 Tray for carrying Scrap

The scrap is stored in a room with length 6 meter, width 3 meter and height 3 meter. The tray is used to carry the scrap. The Fig 3.4 shows the scrap kept in the try for moving it to the scrap storage room. When the scrap is full in the tray the weight of the scrap is approximately 25kg. In the room the height of the scrap goes up to 1.5 meter. On a daily basis 2 to 4 trays of scrap are removed from the shop floor. The time taken to remove scraps from the floor is 1.5 to 2 hours on a daily basis.

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CHAPTER 4

DESIGN, FABRICATION AND TESTING OF THE MACHINE 4. Some Theory of Hydraulics and Pneumatics [5]

A detailed study was conducted to do the design of the hydraulics. Before making the circuit, the theory of hydraulics was researched and studied.

Fig 4.1 Picture that demonstrates Pascal’s Law

4.1 Pascal’s Law

Pascal’s law states that when a confined fluid is placed under pressure, the pressure is transmitted equally in all directions and on all faces of the container. This is the principle used to extend the ram on a hydraulic cylinder. By applying a force to move the piston on one end, the piston on the other end will move the same distance with same amount of force. Fig 4.1 shown above shows an illustration of the above theory.

4.2 Hydraulic “Leverage”

The Fig 4.2 for explaining the hydraulic leverage is shown below. The leverage we get when we increase the area is explained in detail after the figure.

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Fig 4.2 Diagram for explaining “Hydraulic Leverage”

We can increase the mechanical advantage to lift a heavier load. This is the principle that allows you to jack up a very heavy object while exerting a small amount of force on the handle of a hydraulic jack. The animated illustration shows that 1 lb. of force exerted on a 1 sq. in. piston, moved 10 in. will lift 10 lbs. a distance of 1 in. with a 10 sq. in. piston on the 'Play' button in the illustration to see a demonstration. The larger piston will move a shorter distance, but provides the mechanical advantage to lift a much heavier load. The mechanical workforce advantage in hydraulics can be thought of as leverage, but it is hydraulic leverage.

4.3 Basic Hydraulic System

Although hydraulic circuit layouts may vary significantly in different applications, many of the components are similar in design or function. The principle behind most hydraulic systems is similar to that of the basic hydraulic jack. Oil from the reservoir is drawn past a check ball into the piston type pump during the piston's up-stroke. When the piston in the pump is pushed downward, oil will be directed past a second check ball into the cylinder. As the pump is actuated up and down, the incoming oil will cause the cylinder ram to extend. The lift cylinder will hold its extended position because the check ball is being seated by the pressure against it from the load side of the cylinder. Because the pump displacement is usually much smaller than the cylinder, each stroke of the

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pump will move the cylinder a very small amount. If the cylinder is required to move at a faster rate, the surface area of the pump piston must be increased and/or the rate which the pump is actuated must be increased. Oil flow gives the cylinder ram its speed of movement and oil pressure is the work force that lifts the load.

Fig 4.3 Basic Hydraulic System

4.4 Reservoir

Here is an example of a reservoir, one of the four basic requirements to make a hydraulic system. This particular reservoir is made of moulded plastic and is from a Greens master riding mower.

Fig 4.4 Reservoir

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4.5 Pump

We can improve the efficiency and increase the versatility of a basic circuit by adding some more sophisticated components and changing the circuit layout. By incorporating a gear pump in place of a hand piston pump, we increase oil flow to the cylinder which will increase the actuation rate of the ram. The image to the right shows a cutaway view of a three section gear pump. We can see the gear sets for all three sections and the input (drive) shaft. A gear pump is a positive displacement pump, meaning that whenever the pump is turning the pump must pump oil. If pump flow is totally blocked, sudden failure of the pump or other component will occur. As the gears in the pump rotate, suction is created at the inlet port of the pump. The fluid is drawn in to the pump and is carried in the spaces between the gear teeth to the discharge port of the pump. At the discharge side of the pump the gear teeth mesh together and the oil is discharged from the pump. Note that the pump creates flow. The pump, by itself, does not create pressure. Pressure results only when there is resistance to flow. You cannot have pressure without flow (or potential flow).

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4.6 Control Valve

The flow from the pump to the cylinder is controlled by a sliding spool valve which can be actuated a hand or foot operated lever or an electric solenoid. The image to the right shows a cutaway of an actual hydraulic control valve. The valve shown in the illustration is open centre valve, meaning that the oil flow is returned to the reservoir when the valve is in the neutral position. The spool valve has the capability to direct fluid flow to either end of the actuator. As the spool is moved, fluid is redirected to one end or the other of the actuator, while fluid being pushed out the other end of the actuator is directed back to reservoir through the valve.

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The design is done in Solid Works 2013. The fabrication of the machine is executed in the Workshop. The testing of the machine was carried out in the Hydraulics Lab.

4.7 Hydraulic Press Cylinder

The hydraulic cylinders are the main part in the case of the scrap bailing press. The main hydraulic cylinder carries the bailing press tool for bailing the scrap. In this hydraulic cylinder the piston makes one forward and retract motion to bail or compress the scrap of most of the scrap types from different machining process which are different type of materials

• Barrles-Tube seamless honed barrels (steel/brass/aluminium) to a micro-finish provide long piston seal life and prevent failure of the cylinder.

• Piston Rod-High strength steel piston rod is precision ground and hard chrome plated and regrinds to ensure anti-corrosion and maximum seal life. The rod material is EN-8.

• Piston-Cast iron

• Cylinder Base-The end of the cylinder is precision bolted the base is threaded & then welding with utmost accuracy and precision.

4.7.1 Die Casting Cylinder

These cylinders are the main part of the scrap bailing press arrangement which carry the die section which are used to compact the incoming scraps. Each cylinder has half section of a cubic die arrangement makes contact and forms a cubic die cavity in which the scraps are feed to bail it into cubes. These cylinders have a dove tail opening in the closed side facilitate their sliding motion over a dove tail saddle to avoid wear and tear of the base of the die cavity section while the piston makes forward and retraction motion. The die cavity section has some holes in the side walls to allow the air between the scraps while pressing or bailing.

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4.8 Hydraulic Control Systems

The scrap bailing press arrangement has three cylinders which are operating by the hydraulic power and control system. They are used to regulate and direct the flow of fluid in the respective pipe lines. The hydraulic control system consists of following,

 Direction control valve  Sequence valves  Pressure relief valve  Check valves

 Oil, pump, tank and oil filters etc. 4.9 Direction Control Valve

The directional control valve used here is 4/3 directional control valve. In this valve there are 4 ports and 3 distinct positions. Oil enters into the valve through filter and pump. Solenoid actuated, spring return mechanism is used in this direction control valve. It is used to control the direction of flow of oil.

4.10 Other Parts

4.10.1 Pressure Relief Valve

Pressure relief valve otherwise called pressure limiting valve which is located between pump and actuator. A relief valve limits the maximum pressure that can be applied to the part of the system which it is connected. It also protects a system from excessive fluid pressure over and above the design pressure limit. It is used where the flow rate and the system pressure are low.

4.10.2 Sequence Valve

The sequence valves are the type of pressure control valve which is used to control the fluid flow to ensure several operations in a particular order of priority in the system. It allows the fluid to operate first phase when the system inlet pressure is within preset value pressure, if the pressure exceeds the pre-set value the flow is diverted to second phase.

4.10.3 Check Valves

The check valve is one type of directional control valve. It is used to allow free flow in only one direction and to prevent any flow in the other

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direction. It blocks the reverse flow of the fluid, so it is otherwise called non-return valves.

4.10.4 Oil Pumps and Oil Filters

The hydraulic oil used here is hydroil or any other mineral oil or any hydraulic oils. The oil filters used here is to remove the impurities from the oil. 4.11 Hydraulic Circuit for the Scrap Compressing Machine[12]

The Fig 4.7 shown below is a simple hydraulic circuit diagram for a scrap compressing machine. The connection is taken from the pump and connected to the control valve. The pump is connected to the reservoir through a filter which filters the dust particles coming out from the circuit.

Fig 4.7 Hydraulic Circuit for Scrap Compressing Machine

Then from control valve two connections is taken and connected to the cylinder. One line from the control valve is simply put in the reservoir tank. So the fluid is pumped to the control valve, by turning retract, the fluid control to the first port is regulated. Then the fluid will push the cylinder to the other end. When retract is released the fluid will low back to the reservoir through the tank line.

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4.12 Pneumatic Control Systems

This system includes various DCV’s, FRL unit, Muffler etc. They are used to regulate and direct the flow of air in the respective pipe lines. The pneumatic system used for the ejector only.

 Directional control valve  FRL unit

 Muffler etc.

4.12.1 Direction Control Valve

The direction control valve used here is 5/2 directional control valve. In this valve there are 5 ports and 3 distinct positions. Solenoid actuated, spring return mechanism is used in this directional control valve. It is used to control the direction of flow of air.

4.12.2 Muffler

The muffler is used to control the noise caused by the air stream flowing into the atmosphere.

4.12.3 FRL Unit

It means filter, regulator and lubricator unit. Filter is used to remove impurities in the compressed air; regulator is used to regulate the pressure of the incoming air, lubricator mix the oil with the air.

The cylinder A and B is connected to the A and B port of Direction Control Valve (DCV). The P port of DCV is connected to the Pump and T port of DCV is connected to the tank line. The power pack consists of a Motor, Pump and an internal relief Valve. The Pump is connected to a External Pressure Relief Valve, Pressure Gauge and to the P port of DCV in series. To operate the Machine the pump is switched on and the lever of the DCV is turned. The fluid from the pump is pumped to Port A and the cylinder will start moving forward and start compressing scrap.

4.13 Testing similar Circuit in Pneumatics

Before moving into fabrication and further analysis of the equipment a similar circuit was tested in pneumatics just to understand the theory and

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working of the system. The Fig 4.8 shown below shows the testing of the pneumatic circuit in the Pneumatic Lab.

Fig 4.8 Testing the Circuit in Pneumatic Lab

The circuit is tested and the connections are figured out. It gave a clear idea on the making of circuit as well as the working of DCV, FCV, PRV, and Cylinder.

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From the Fig 4.9 we can see the input P line a connection is taken and connected to the DC Valve and Flow Control Valve and from there A and B line is connected to the Cylinder. A Pressure relief valve is connected to the output from B port of the cylinder back to the compressor.

4.14 Welded Joint Types [6]

The American Welding Society defines a joint as

“the manner in which materials fit together.” As shown in Fig 4.10 there are five basic types of weld joints

• Butt joint • T-joint • Lap joint • Corner joint • Edge joint

In the machine fabricated, corner joints are the joints are done all along. Fig 4.10 shows different types of welded joints.

Fig 4.10 Different types of welded Joints

In the machine fabricated fillet weld is the maximum used one. The Fig 4.11 shown below is the diagram for a fillet weld.

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In this type of weld two plates are held together as shown in the figure and welded. The calculation for testing the sustainability of the fillet weld in the machine comes in the following section.

4.15 Shielded Metal Arc Welding [2]

Shielded Metal Arc Welding is used for welding the machine. In that an electrode is used to make the weld. The machine is connected to the AC supply. It has got a control panel to control the power. The work cable is touched with the work piece. The electrode holder holds the electrode. When the electrode touches the part to be welded Arc will be produced which will melt the electrode to form solidified slag and weld metal.

Fig 4.12 Shielded Metal Arc Welding

The Fig 4.12 shows a typical Shielded Metal Arc Welding. The second part of the picture shows what happens when the electrode is touched to the base metal. A shielding gas is produced to prevent oxidation. The electrode melts and the weld metal and solidified slag is produced.

4.16 Force Required for Compression

From literature it is found that the force which is applied for a scrap compressor is 125 Tons for the compressing room size of 1200 700 600mm. The force required for the compressing scrap in the new machine of compressing room size 180 180 180mm.

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=

125000/1200 700 = F1/180 180

F1 = 4821.42kg

F1 =4.821Tons

Cylinder diameter required = 40 mm

Stroke Length = 200mm

Pressure = 50 bar

Pressure Control Valve (Relief Valve) = 75bar

- (1)

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4.17 Design Concept Developed

The Fig 4.13 shown below is the concept developed as per the suggestion from the company where the study was conducted. The concept is to compress the scrap straight away from the lathe, drilling, milling machine and compress and make it into blocks.

Fig 4.13 Initial Concept of the Scrap Compressing Machine

The Fig 4.13 is the initial concept developed. The screw conveyor takes the scrap from the lathe and delivers into the compression box. Then a hydraulic cylinder is used to compress the scrap to a block.

4.18 Costing

Different costs involved in the scrap management are, on a daily basis two helpers of wages Rs 6000/month (25 working days) work for 2 hours. A room of size 6 meter long, 3 meter wide and 3 meter height is dedicated for scrap storage.

Storage Cost - 4000 INR/month Manpower Cost - 2400 INR/month

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Total Cost of scrap removal and storage is 6400 INR/month. This is the total cost before installing the machine.

The cost of electricity in Tamilnadu for Industries is 8 INR/unit. A 1 Hp motor is 746 Watts. A 1000 Watts motor will consume 1 Unit of electricity in one Hour. So if the power pack has got a motor of 1HP then it will consume 0.746 units of Electricity which will cost 5.968 INR/hour. So the total power consumption cost for a month is 358 INR. From the literature it is found that the compressibility ratio is 5:1. So the storage space required after compressing the whole scrap is one 5th_{of the current space. So the cost of storage will be 800} INR. If we implement the conveyer based scrap compressor then we can assume the number of person working for two hours can be reduced from two to one. So the cost of manpower will become 1200 INR for a month. So if we add these factors then the total cost of scrap removal will become 2358 INR/month. This is less than the half of current cost. The prototype will cost 15000 INR excluding the power pack which costs 30000 INR. The cost savings per month after the installation of the scrap compressor is 4042 INR. So the machine will Break Even in 11 months from its installation.

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CHAPTER 5

5. Finite Element Analysis (FEA)

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.

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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.

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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/m}2_{. 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}

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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.

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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.

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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

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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 cm}3_{. 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.

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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.

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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

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Name

Reg. No and Section

Father' s Name, Phone number Address for communication

Contact details

Educational Qualifications: SSLC (% of marks and Institution)

B. Tech (up to VII Sem) Future plan

In-plant training

Placement status (Company Name)

Project title (UG) Project title (PG)/ Guide Add on programs attended

Conference attended Papers Published with details

Academic and sports awards received

Software skills developed Previous experience if any Date

BOBBY P PAUL

PR11ME1009, II M.TECH (DESIGN)

PROF P PAUL, +919447208801 Photo

URUMPACKAL HOUSE, MANNARKAYAM P.O, VIA PONKUNNAM, KOTTAYAM DIST, KERALA, INDIA, PIN-686506

Phone : 04828-202955

email: [email protected]

MASTER OF TECHNOLOGY

69.66 HSC/ Diploma ( As 76.6

above)

60.03 M. Tech (up to III Sem) 72

Teaching Area of Interest Product Design

VISHAL PRECISION IAESTE Nil

PRODUCTS PVT LTD, COIMBATHORE

NIL Mentor name Mr Walter Vincent

COMPILING ECONOMIC ORDER QUANTITY USING C++

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 19}TH

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

Scrap chip compressing machine

DESIGN OF A SCRAP COMPRESSING MACHINE

FOR SMALL SCALE INDUSTRIES

BOBBY P PAUL

(REG. NO: PR11ME1009)

MASTER OF TECHNOLOGY

IN

MECHANICAL ENGINEERING (DESIGN)

Dr. S DARIUS GNANARAJ

DEPARTMENT OF MECHANICAL ENGINEERING

SCHOOL OF MECHANICAL SCIENCES

KARUNYA UNIVERSITY

BONAFIDE CERTIFICATE

This is to certify that the project report entitled, “DESIGN OF A SCRAP

COMPRESSING MACHINE FOR SMALL SCALE INDUSTRIES” is a

bonafide record of work of BOBBY P PAUL (PR11ME1009) who carried

out the project work under my supervision during the academic year

2012-2013.

SIGNATURE

DR. DARIUSGNANARAJ

SIGNATURE

Dr. M. SEKAR

Submitted for the (Full Semester Project) Viva Voce held on………

ACKNOWLEDGEMENT

CONTENTS

LIST OF FIGURES

LIST OF NOMENCLATURE

CHAPTER 1

INTRODUCTION

CHAPTER 2

LITERATURE SURVEY

=

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