DESIGN OF A SCRAP COMPRESSING MACHINE

FOR SMALL SCALE INDUSTRIES

a project report Submitted b
!O!!" P PAUL
#REG$ NO% PR&&ME&''()
i* partia+ ,u+,i+me*t ,or t-e a.ard o, t-e de/ree o,
MASTER OF TECHNOLOG"
IN
MECHANICAL ENGINEERING #DESIGN)
U*der t-e /uida*ce o,
Dr$ S DARIUS GNANARA0
Dea* Re1earc-
DEPARTMENT OF MECHANICAL ENGINEERING
SCHOOL OF MECHANICAL SCIENCES
2ARUN"A UNI3ERSIT"
#2aru*a I*1titute o, Tec-*o+o/ a*d Scie*ce1)
#Dec+ared a1 Deemed4to4be4u*der Sec45 o, t-e UGC Act6 &(78)
2aru*a Na/ar6 Coimbatore 4 89& &&96 INDIA$
APRIL :'&5
!ONAFIDE CERTIFICATE
T-i1 i1 to certi, t-at t-e project report e*tit+ed6 ;DESIGN OF A SCRAP
COMPRESSING MACHINE FOR SMALL SCALE INDUSTRIES< i1 a
bo*a,ide record o, .or= o, !O!!" P PAUL #PR&&ME&''() .-o carried
out t-e project .or= u*der m 1uper>i1io* duri*/ t-e academic ear :'&:4
:'&5$
SIGNATURE
DR$ DARIUSGNANARA0
Pro,e11or
SUPER3ISOR
DEAN RESEARCH
2ARUN"A UNI3ERSIT"
SIGNATURE
Dr$ M$ SE2AR
Pro,e11or
HEAD OF THE DEPARTMENT
Departme*t o, Mec-a*ica+ E*/i*eeri*/
Submitted ,or t-e #Fu++ Seme1ter Project) 3i>a 3oce -e+d o*???????
????????$$$
I*ter*a+ E@ami*er E@ter*a+ E@ami*er
ii
AC2NOALEDGEMENT
At t-e out1et6 I e@pre11 m /ratitude to t-e ALMIGHT" GOD .-o -a1 bee*
.it- me duri*/ eac- a*d e>er 1tep t-at I -a>e ta=e* to.ard1 t-e comp+etio*
o, t-i1 project$
I t-a*= our be+o>ed ,ou*der +ate Dr$ D$G$S$ DHINA2ARAN6 P-$D$6 a*d
our Ho*orab+e C-a*ce++or Dr$ PAUL DHINA2ARAN6 P-$D$6 ,or pro>idi*/ me
t-e educati>e i*,ra1tructure a*d +ear*i*/ ambie*ce6 .-ic- moti>ated me to a
/reat e@te*t$ I .i1- to t-a*= t-e Ma*a/eme*t o, 2aru*a U*i>er1it a*d our
3ice C-a*ce++or6 Dr$ E$0$ 0AMES6 P-$D$6 a*d Re/i1trar6
Dr$ C$ 0OSEPH 2ENNAD"6 P-$D$6 ,or e@te*di*/ a++ ,aci+itie1$
I .ou+d +i=e to p+ace m -eart4,e+t t-a*=1 a*d /ratitude to
Dr$ T$ 3$ CHRIST"6 M$E6 P-$D$6 Director6 Sc-oo+ o, Mec-a*ica+ Scie*ce1 ,or
-i1 e*coura/eme*t a*d /uida*ce$ I e@te*d m t-a*=1 to
Dr$ M$ SE2AR6 M$E6 P-$D$6 Head o, t-e Departme*t6 Sc-oo+ o, Mec-a*ica+
Scie*ce$
I t-a*= .it- deep 1e*1e o, /ratitude to m /uide
Dr$ S$ DARIUS GNANARA06 M$E6 P-$D$6 Dea* Re1earc-6 ,or -i1 e@-i+arati*/
1uper>i1io*6 time+ 1u//e1tio* a*d /uida*ce duri*/ a++ p-a1e o, t-i1 .or=$
I t-a*= t-e co4ordi*atio* a*d -e+p o, m e@ter*a+ /uide Mr$
0$ CHANDRAN a*d Mr$ 0A"SEELAN6 3i1-a+ Preci1io* Product1 P>t Ltd6
Coimbatore6 Tami+*adu ,or t-eir co*1ta*t 1upport6 -e+pi*/ -a*d a*d
e*coura/eme*t i* t-e project$
I .ou+d ta=e t-i1 opportu*it to t-a*= our C+a11 Ad>i1or
Mr$ AALTER6 M$Tec-6 a*d A11i1ta*t Pro,e11or .-o -ad bee* a+.a1 t-ere ,or
u1$ A+1o6 I .ou+d +i=e to t-a*= a++ t-e teac-i*/ ,acu+t member1 a*d 1upporti*/
Sta,, o, our departme*t ,or co4operati*/ a*d arra*/i*/ t-e *ece11ar ,aci+itie1$
I .ou+d +i=e to t-a*= Dea* Re1earc- ,or /ra*ti*/ me *ece11ar ,u*di*/ ,rom
2STPG ,or t-e project e@ecutio*$ I .ou+d +i=e to co*>e /ratitude to m PARENTS
.-o1e praer1 a*d b+e11i*/ .-ere a+.a1 t-ere .it- me$
iii
A!STRACT
Scrap i1 o*e o, t-e mo1t i/*ored .a1te1 i* a* I*du1tr$ Scarcit a*d
ri1i*/ o, commodit price1 i*crea1e t-e importa*ce o, 1crap recc+i*/$ T-ere are
ma* ad>a*ta/e1 i* compre11i*/ 1crap$ T-e 1tora/e 1pace .i++ be 1a>ed t-u1
eit-er t-e 1iBe o, t-e 1tora/e room ca* be reduced or more 1crap ca* be 1tored i*
t-e 1pace a>ai+ab+e Tra*1portatio* co1t .i++ be reduced a1 more amou*t o, 1crap
ca* be tra*1ported at a time$ Ha*d+i*/ o, t-e 1crap .i++ become ea1ier a1 t-e are
made i*to b+oc=1$ So a 1tud .a1 co*ducted i* a 1ma++ 1ca+e i*du1tr .-ic- dea+1
.it- 0i/16 Fi@ture1 a*d ma*u,acture1 ma* 1ma++ mac-i*e1 +i=e -ea> dut
pri*ter1 etc$ ReCuired data ,or t-e de1i/* o, t-e 1crap compre11or6 ,or t-e
-drau+ic circuit6 t-e compre11io* ratio6 ,orce reCuired ,or compre11io* are
co++ected ,rom t-e Literature Sur>e$ T-e curre*t practice o, 1crap remo>a+ a*d
1tora/e i* t-e i*du1tr i1 1-o.* u1i*/ p-oto/rap-1$ T-e ca+cu+atio*1 ,or arri>i*/
at t-e ,orce reCuired ,or compactio* i1 1-o.*$ T-e -drau+ic circuit dia/ram a*d
te1ti*/ o, a 1imi+ar circuit i* p*eumatic te1t be*c- are e@p+ai*ed$ Co1t o, t-e
prototpe a*d t-e brea= e>e* period are di1cu11ed$ Fi*ite e+eme*t a*a+1i1 o, t-e
1o+id mode+ i1 do*e i* So+id Aor=1 :'&'$ T-e de,+ectio* o, t-e p+ate .-e* a
pre11ure i1 app+ied i1 ,ou*d$ T-e de1i/* ca+cu+atio*1 ,or .e+di*/ a*d t-e ,ati/ue
a*a+1i1 co*1ideri*/ ,actor o, 1a,et i1 a+1o per,ormed$ Fabricatio* a*d te1ti*/ o,
t-e mac-i*e i1 e@ecuted i* t-e Aor= S-op a*d Hdrau+ic1 Lab$
iv
CONTENTS
CHAPTER PAGE NO$
!ONAFIDE CERTIFICATE ii
AC2NOALEDGEMENT iii
A!STRACT i>
TA!LE OF CONTENT >
LIST OF FIGURES >iii
LIST OF NOMENCLATURE @
&$ INTRODUCTION
&$& About t-e Compa* &
&$: Commo* Scrap !ai+er1 A>ai+ab+e i* t-e Mar=et :
&$:$& Trip+e Compre11io* Scrap !ai+i*/ Pre11 :
&$:$: Doub+e Compre11io* Scrap !ai+er 5
&$:$5 Si*/+e Compre11io* Scrap !ai+er 5
&$5 Aim 5
&$9 Scope o, t-e Project 5
:$ LITERATURE SUR3E" 7
:$& T-e Re1earc- o* S-reddi*/ Mode+1 o, Li/-t Meta+ Scrap o,
E*d o, Li,e 3e-ic+e1 7
:$: Scrap Compre11io* Mac-i*e1 4 o>er>ie. 8
:$5 Scrap Meta+ !ai+i*/ Pre11 #SM!4F&:7) Supp+ied b E*rapt
Mac-i*e Co Ltd 8
:$9 Scrap S-ear Mac-i*e .it- Adju1tab+e T-roat D
:$7 Scrap Materia+ S-reddi*/ a*d Compre11i*/ Apparatu1 a*d S1tem D
:$8 Creatio* o, Faci+itie1 ,or e,,ecti>e ma*a/eme*t o, 1crap at rai+.a
U*it1 E
>
5$ CURRENT PRACTICE OF SCRAP REMO3AL AND
STORAGE IN 3ISHAL PRECISION PRODUCTS P3T LTD
5$& Curre*t Practice o, Scrap Remo>a+ a*d Stora/e &'
9$ DESIGN6 FA!RICATION AND TESTING OF THE MACHINE
9$& Pa1ca+F1 La. &5
9$: Hdrau+ic Le>era/e &9
9$5 !a1ic Hdrau+ic S1tem &9
9$9 Re1er>oir &7
9$7 Pump &8
9$8 Co*tro+ 3a+>e &D
9$D Hdrau+ic Pre11 C+i*der &E
9$D$& Die Ca1ti*/ C+i*der &E
9$E Hdrau+ic Co*tro+ S1tem &(
9$( Directio* Co*tro+ 3a+>e &(
9$&' Ot-er Part1 &(
9$&'$& Pre11ure Re+ie, 3a+>e &(
9$&'$: SeCue*ce 3a+>e &(
9$&'$5 C-ec= 3a+>e &(
9$&'$9 Oi+ Pump1 a*d Oi+ Fi+ter1 :'
9$&& Hdrau+ic Circuit ,or t-e Scrap Compre11i*/ Mac-i*e :'
9$&: P*eumatic Co*tro+ S1tem1 :&
9$&:$& Directio* Co*tro+ 3a+>e :&
9$&:$: Mu,,+er :&
9$&:$5 FRL U*it :&
9$&5 Te1ti*/ Simi+ar Circuit i* P*eumatic1 :&
9$&9 Ae+ded 0oi* Tpe1 :5
9$&7 S-ie+ded Meta+ Arc Ae+di*/ :9
9$&8 Force ReCuired ,or Compre11io* :9
9$&D De1i/* Co*cept De>e+oped :D
9$&E Co1ti*/ :D
>i
7$ FINITE ELEMENT ANAL"SIS
7$& De1i/* ,or Fabricatio* a*d FEA A*a+1i1 :(
7$: So+id !od ,or FEA A*a+1i1 5'
7$5 Me1-i*/ ,or FEA 5'
7$9 >o* Mi1e1 Stre11 5&
7$7 De,ormatio* ,or t-e App+ied Load 5:
8$ FA!RICATION AND TESTING
8$& Fabricatio* 55
8$: Te1ti*/ o, t-e ,abricated Scrap Compre11i*/ Mac-i*e 59
D$ CONCLUSION
REFERENCE
RESUME
>ii
LIST OF FIGURES
Fi/ure No$ De1criptio* Pa/e No$
5$& Scrap +i*/ o* 1-op ,+oor &'
5$: Ma/*et ,or remo>i*/ Scrap1 &&
5$5 Scrap Stora/e &&
5$9 Tra ,or carri*/ Scrap &:
9$& Picture t-at demo*1trate1 Pa1ca+F1 La. &5
9$: Dia/ram ,or E@p+ai*i*/ Hdrau+ic Le>era/e &9
9$5 !a1ic Hdrau+ic S1tem &7
9$9 Re1er>oir &7
9$7 Pump &8
9$8 Co*tro+ 3a+>e &D
9$D Hdrau+ic Circuit ,or Scrap Compre11i*/ Mac-i*e :'
9$E Te1ti*/ t-e Circuit i* P*eumatic Lab ::
9$( P*eumatic Circuit ::
9$&' Di,,ere*t tpe1 o, .e+ded joi*t1 :5
9$&& Fi++et Ae+d :5
9$&: S-ie+ded Meta+ Arc Ae+di*/ :9
9$&5 I*itia+ Co*cept o, t-e Scrap Compre11i*/ Mac-i*e :D
7$& So+id Mode+ o, t-e Scrap Compre11i*/ Mac-i*e :(
7$: So+id bod ,or FEA 5'
7$5 T-e tria*/u+ar me1-i*/ i1 do*e ,or doi*/ FEA 5&
7$9 >o* Mi1e1 Stre11 5&
7$7 T-e De,ormatio* ,or App+ied Load 5:
8$& Detai+ed Dra.i*/ o, t-e Mac-i*e 55
8$: Te1ti*/ o, Scrap Compre11i*/ Mac-i*e 59
8$5 T-e Compre11ed Scrap 57
>iii
LIST OF NOMENCLATURE
A!!RE3IATIONS ACRON"MS
CNC Computer Numeric Co*tro+
CMM Coordi*ate Mea1uri*/ Mac-i*e
EL3 E*d4o,4Li,e 3e-ic+e
LMS Li/-t Meta+ Scrap
ELHA E*d o, Li,e 3e-ic+e1 a*d Hou1e Ho+d
App+ia*ce1
SM! Scrap Meta+ !a+i*/ Pre11
DC3 Directio* Co*tro+ 3a+>e
FC3 F+o. Co*tro+ 3a+>e
PR3 Pre11ure Re+ie, 3a+>e
INR I*dia* Rupee1
FEA Fi*ite E+eme*t A*a+1i1
ix
CHAPTER &
INTRODUCTION
&$& About t-e Compa*
T-e compa* i* .-ic- t-e 1tud .a1 co*ducted 1tarted i* t-e ear &(E8$
T-e are 1ucce11,u++ cateri*/ to E*/i*eeri*/ i*du1trie1 ,or o>er a decade *o.$
T-e -a>e tec-*ica+ e@perti1e6 1trict Cua+it co*tro+6 competiti>e prici*/ a*d
prompt de+i>er ca* -e+p ot-er compa*ie1 to reduce de+i>er time a*d i*crea1e
it1 producti>it$ T-e compa* ma=e1 Sta*dard Mou+d !a1e16 Ma*u,acture1
Preci1io* Compo*e*t16 a*d A11emb+e1 Sub4A11emb+ie1 ,or Pri*ti*/6 Paper6
Te@ti+e6 Aero G Oi+ tpe o, Mac-i*erie1 Aor+d.ide$ T-e compa* -a1 a++ t-e
reCuired ,aci+itie1 ,or mac-i*i*/ a*d i*1pectio*6 eCuipped Ait- CNC Mac-i*i*/
Ce*tre1 G Ot-er Mac-i*erie16 CMM G Hei/-t Ma1ter$ T-e ma*u,acture a1 per
Cu1tomer Dra.i*/1 G Speci,icatio*1 a*d -a1 Cua+i,ied per1o**e+ to meet a*
tec-*ica+ dema*d$ T-i1 paper report1 t-e er/o*omic de1i/* o, a 1crap
compre11or to compre11 t-e 1crap materia+ comi*/ out ,rom 1ma++ mac-i*erie1
+i=e +at-e16 dri++i*/ mac-i*e16 mi++i*/ mac-i*e1 etc$ T-e project i1 propo1ed b
t-e i*du1tr becau1e t-e 1crap1 comi*/ out ,rom t-e mac-i*e -a1 to be remo>ed
e>er .ee= a1 t-e 1pace a++ocated .i++ become ,u++ i* a .ee=$ It a+1o co*1ume1
+ot o, ma*po.er to do t-e c+ea*i*/$
T-e ma*a/eme*t o, 1crap i1 o*e o, t-e mo1t a>oided a*d di,,icu+t part i* a*
i*du1tr$ T-e 1crap ,rom +at-e6 dri++i*/ mac-i*e a*d mi++i*/ mac-i*e +ie o* t-e 1-op
,+oor ma=e1 t-e .or= di,,icu+t$ A+1o t-e 1crap ta=e1 more 1pace t-a* reCuired$
Ma*ua+ -a*d+i*/ o, 1crap materia+ po1e1 prob+em i* i*du1trie1$ More >o+ume a*d
.ei/-t ca* be tra*1ported i, t-e 1crap materia+ i1 compre11ed$ T-i1 met-od a+1o -e+p1
i* 1e++i*/ 1crap1 a*d recc+i*/ eco*omica++$
For compre11i*/ t-e 1crap6 di,,ere*t tec-*o+o/ie1 ca* be u1ed$
Mec-a*ica+6 Hdrau+ic1 or P*eumatic 11tem1 ca* be de>e+oped to compre11 t-e
1crap$ Hdrau+ic tec-*o+o/ i1 1e+ected a1 it ca* de+i>er more ,orce o* t-e 1crap
to compre11$ Picture1 o, t-e 1crap1 o* t-e ,+oor a*d t-e dumpi*/ ard .ere
1
recorded$ A /e*era+ 1tud .a1 co*ducted to ,i*d t-e time ta=e* to remo>e t-e
1crap a*d t-e co1t be-i*d t-e remo>a+$ A /e*era+ Cue1tio* a*d a*1.er 1e11io* .a1
co*ducted to ta=e ,eedbac= ,rom t-e emp+oee1 a*d t-e ma*a/eme*t about t-e
curre*t 1crap ma*a/eme*t$
T-i1 project i1 t-e approac- o, de1i/*i*/ t-e 1crap compre11or a*d to
de>e+op a co*cept b i*corporati*/ Er/o*omic pri*cip+e1$ T-e co*cept
de>e+oped i1 ,urt-er de>e+oped i* a detai+ed .a to ma=e t-e mac-i*e to do t-e job
e,,icie*t+ a*d e,,ecti>e+$ A detai+ed co1ti*/ i1 do*e to ,i*d t-e co1t o, t-e
mac-i*e$ T-e1e detai+1 .i++ -e+p 1ma++ 1ca+e i*du1trie1 to i*1ta++ a 1crap
compre11or$ T-i1 project i1 importa*t i* i*du1tria+ poi*t o, >ie. becau1e it 1a>e1 co1t
b reduci*/ reCuired ma* po.er ,or 1crap remo>a+6 a*d it ma=e1 t-e 1crap -a*d+i*/
a*d tra*1portatio* ea1ier$
At t-e mome*t t-ere are *o 1crap bai+er1 1peci,ica++ made ,or
compre11i*/ 1crap1 comi*/ out ,rom +at-e16 dri++i*/ a*d mi++i*/ mac-i*e1$ T-ere are
ma* +ar/e 1iBe 1crap bai+er1 a>ai+ab+e i* t-e mar=et ,or compre11i*/ 1crap1$ T-e
idea be-i*d doi*/ t-i1 project i1 to ta=e a pump +i*e out ,rom a* -drau+ic pac=1
a>ai+ab+e i* t-e i*du1tr a*d co**ect it to t-e mac-i*e made a*d 1crap1 ca* be
compre11ed$
&$: Commo* Scrap !ai+er1 A>ai+ab+e i* t-e Mar=et
T-e detai+ed de1criptio* o, 1ome 1crap bai+er1 readi+ a>ai+ab+e i* t-e
mar=et are /i>e* be+o.$
&$:$&$ Trip+e Compre11io* Scrap !ai+i*/ Pre11
Trip+e compre11io* ba+er1 are u1ed ,or reduci*/ t-ree dime*1io*1 o, t-e 1crap
materia+ b u1i*/ -drau+ic ,orce ,rom t-ree di,,ere*t a*/+e1$ T-e t.o -oriBo*ta+
c+i*der1 are arra*/ed at ri/-t a*/+e1 to eac- ot-er$ 3ertica+ reductio* /e*era++ ta=e1
p+ace b -drau+ic pre11ure o* t-e +id c+i*der$ O*e o, t-e -oriBo*ta+ c+i*der1
pre11e1 t-e 1crap a/ai*1t t-e ejectio* door o, t-e ba+er$ T-i1 door i1 rai1ed
-drau+ica++ a,ter ba+i*/ i1 comp+ete$ T-e bu*d+e i1 t-e* remo>ed ,rom t-e c-amber b
-oriBo*ta+ c+i*der$
2
T-e ,eedi*/ o, t-e 1crap i1 do*e .it- Sma++ ba+er1$ Meta+ ma be ,ed i*to
t-e pre11 bo@ or c-amber ma*ua++ or b mea*1 o, a +oadi*/ -opper$ A ,air+
+ar/e bi* i1 =ept o* t-e 1ide or ,ro*t o, t-e boi+er$ T-e ad>a*ta/e o, -opper i1 t-at
t-e ca* be ,i++ed duri*/ t-e ba+i*/ cc+e6 .-ic- ma ta=e a mi*ute or more$ T-e
-opper a+1o add1 to 1a,et o, t-e operator a1 ma*ua+ ,i+i*/ i*>o+>e1 /reater ri1=$
&$:$: Doub+e Compre11io* Scrap !ai+i*/ Pre11
Scrap ba+er1 are u1ed ,or reduci*/ t-e 1crap materia+1 i* t.o dime*1io*1 b
u1i*/ -drau+ic ,orce ,rom t.o di,,ere*t a*/+e1$ T-e ba+e de*1it i1 1+i/-t+ +e11
t-a* trip+e compre11io* ba+er$ T-e ba+er1 -a>e o*e c+i*der ,i@ed i*
-oriBo*ta+ po1itio*$ 3ertica+ reductio* u1ua++ ta=e1 p+ace b -drau+ic pre11ure o*
t-e +id c+i*der$ T-e -oriBo*ta+ c+i*der pre11e1 t-e 1crap a/ai*1t t-e ejectio* door
o, t-e ba+er$ T-i1 door ca* be rai1ed or ope*ed -drau+ica++ a,ter t-e proce11
o, ba+i*/ i1 comp+ete$ T-e 1crap bu*d+e i1 t-e* remo>ed ,rom t-e c-amber b
-oriBo*ta+ c+i*der$
&$:$5 Trip+e Compre11io* Scrap !ai+i*/ Pre11
HoriBo*ta+ tpe 1i*/+e compre11io* 1crap mac-i*e1 are u1ed ,or reduci*/
o*+ 1i*/+e dime*1io* o, t-e meta++ic 1crap$ It u1e1 t-e compre11io* ,orce
/e*erated b t-e -drau+ic c+i*der$ T-e e@it door1 a*d +id ca* be ope*ed
ma*ua++ b t-e operator$ Our 1i*/+e compre11io* 1crap ba+er1 ca* be
cu1tomiBed a1 per t-e 1peci,ic reCuireme*t1 o, t-e c+ie*t1$
&$5 Aim
To de1i/* a 1crap compre11i*/ mac-i*e to compre11 t-e 1crap materia+ come1 out
,rom 1ma++ mac-i*erie1 +i=e +at-e16 dri++i*/ mac-i*e1 etc$
&$9 Scope o, t-e Project
Scrap1 ca* be compre11ed to create 1ma++ b+oc=1$
Space ca* be 1a>ed i* t-e i*du1tr$
Co1t o, 1crap tra*1portatio* ca* be 1a>ed$
3
More 1crap materia+ ca* be tra*1ported$
Scrap recc+i*/ .i++ become ea1ier$
T-e e,,icie*c o, t-e compa* ca* be mea1ured$
Aa1ta/e o, 1crap b ru1ti*/ a*d /oi*/ i*to mud i1 a>oided$
4
CHAPTER :
LITERATURE SUR3E"
:$& T-e Re1earc- o* S-reddi*/ Mode+1 o, Li/-t Meta+ Scrap o, E*d4o,4+i,e 3e-ic+e1
H&I
Accordi*/ to t-e Aut-or1 #Liu 0ia*@io*/ et a+6 :'&:) t-e paper tit+ed ;T-e
Re1earc- o* S-reddi*/ Mode+1 o, Li/-t Meta+ Scrap o, E*d4o,4+i,e 3e-ic+e1 a*d
Hou1e-o+d App+ia*ce1< A detai+ed de1criptio* o, de1i/*6 de>e+opme*t a*d
te1ti*/ o, t-e mac-i*e i1 i++u1trated$ T-e objecti>e o, t-e re1earc- i1 to ,i*d
1o+utio*1 to reu1e o, e*d4o,4+i,e >e-ic+e1 a*d -ou1e-o+d app+ia*ce1 #EL3 a*d
ELHA)$ O* t-e ba1i1 o, t-e .or=i*/ pri*cip+e o, 1-redder16 t-e e@perime*ta+
1-reddi*/ i*1ta++atio* ,or Li/-t Meta+ Scrap #LMS) .a1 co*1tructed$ Ait- t-e
-e+p o, a p-otoe+ectrica+ micro1cope .it- 7' time1 ma/*i,i*/ po.er6 t-e ,eature
o, LMS 1ur,ace appeara*ce6 i*c+udi*/ 1ur,ace 1cratc-e16 .a1 acCuired be,ore a*d
a,ter te1ti*/6 re1pecti>e+$ T-rou/- a*a+1e1 o, e@perime*ta+ re1u+t16 1ome
/e*era+ co*c+u1io*1 .ere reac-ed .-ic- t-o1e 1ma++ crac=16 i* t-e 1ur,ace o,
LMS t-at are co*ti*ua++ 1truc= b Impacti*/ too+16 ,ormed duri*/ ma*u,acture6
ori/i*ate >er 1e>ere co*ce*tratio*1 o, 1tre11 a*d 1trai*J t-e co*ce*tratio*1 o,
1tre11 a*d 1trai* i*duce 1tabi+it +o116 e@te*1io*6 co**ectio*6 per,oratio* o, 1ma++
crac=1 o* t-e 1ur,ace o, LMSJ a,ter t-at 1i*/+e ,ra/me*t1 #:''mmK:''mm) are
tor* o,, ,rom t-e +ar/e p+ate41-aped o, LMS$ U*der t-e /uida*ce o, a*a+tica+
Stud6 dama/i*/ a*d 1-reddi*/ mode1 o, LMS are i*>e1ti/ated b u1i*/
e@perime*t1$ T-e 1ucce11,u+ i*>e1ti/atio* o, 1-reddi*/ mode+ o, EL3 a*d
ELHA .i++ bui+d t-e mode+1 o, t-eir 1-reddi*/ proce11$
A,ter t-e e@perime*ta+ a*d a*a+tica+ i*>e1ti/atio* o, t-e 1tarti*/ proce11
o, LMS6 t-e ,e++o. re1u+t1 .ere ac-ie>ed$ Fir1t poi*t% T-ere are ma* 1cratc-e1
a*d ru1t 1tai*1 i* t-e 1pecime* 1ur,ace6 ,or t-e i*itia+ proce11i*/ a*d ope*4air
depo1iti*/$ I* ,act6 t-e1e 1ur,ace de,ect1 or crac=1 are t-e importa*t rea1o* to
bri*/ t-e LMS to 1tart$ I* t-e 1tarti*/ te1t6 t-e /+oba+ be*di*/ de,ormatio* ma=e1
1pecime* to /i>e ri1e to 1e>ere co*ce*tratio*1 o, 1tre11 a*d 1trai* at ori/i*a+
5
1ur,ace crac= tip$ T-ird poi*t% T-e impact o, 1.i*/ -ammer tip bri*/1 1pecime* to
+oca+ ti* 1u*=e* de,ormatio* t-at e@acerbate1 t-e ori/i*a+ de,ect1 a*d crac= o*
1ur,ace o, LMS 1tabi+it +o116 propa/atio*6 e@te*1io*6 co**ectio*6 per,oratio*$ Fourt-
poi*t% T-e 1i*/+e ,ra/me*t1 #:''mmK:''mm) are tor* o,, ,rom t-e +ar/e p+ate4
1-aped o, LMS e>e*tua++ b co*tro++i*/ t-e e@pa*1i>e directio* o, t-e crac=4
tip16 a*d t-e purpo1e o, reco>eri*/ meta+ 1crap i1 ac-ie>ed$ Accordi*/ to TORO
U*i>er1it tec-*ica+ trai*i*/ ma*ua+ o* Hdrau+ic1 e@p+ai*1 a++ about -drau+ic1
a*d -drau+ic circuit1$ T-e reCuired circuit o, t-e project i1 de>e+oped .it- t-e -e+p
o, t-i1 boo=$
:$: Scrap compre11io* mac-i*e14 o>er>ie. H9I
Accordi*/ to t-e Aut-or #S$ Dariu1 G*a*araj :'&5) t-e paper tit+ed ;Scrap
compre11io* mac-i*e14 o>er>ie.< e@p+ai*1 t-e 1cope o, ma=i*/ a 1crap
Compre11i*/ Mac-i*e ,or 1ma++ 1ca+e i*du1trie1$ It de1cribe1 a++ about t-e
di,,ere*t 1crap compre11or1 a>ai+ab+e a*d it1 re+e>a*ce i* t-e i*du1tr ,or better
1a,et6 producti>it a*d er/o*omic1$ It a+1o -i/-+i/-t1 about t-e accumu+atio* o,
1crap i* t-e i*du1tr a*d t-e prob+em1 i*>o+>ed i* di1po1a+ o, t-e 1crap$ Idea1 ,or
de1i/*i*/ a 1crap compre11or u1i*/ er/o*omic pri*cip+e1 at a +o.er co1t are a+1o
i++u1trated i* t-i1 paper$ It a+1o co*1ider1 t-e be1t po1ture1 o, t-e peop+e
co++ecti*/ t-e 1crap$
:$5 Scrap Meta+ !a+i*/ Pre11 #SM!4F&:7) Supp+ied b E*rapt Mac-i*e Co$6 Ltd HDI
Accordi*/ to E+ectro*ic 1ource Scrap Meta+ !a+i*/ Pre11 #SM!4F&:7)
Supp+ied b E*rapt Mac-i*e Co$6 Ltd /i>e1 t-e 1peci,icatio* ,or 1crap room a*d t-e
ma@imum ,orce t-at ca* be app+ied ,or t-at 1crap room$ Accordi*/ to
E+ectro*ic 1ource Hdrau+ic1 a*d P*eumatic1 /i>e1 t-e picture o, t-e Hdrau+ic
Circuit$ Accordi*/ to E+ectro*ic 1ource ILS Director /i>e1 t-e detai+1 o* 1crap
compre11io* ratio$
6
:$9 Scrap S-ear Mac-i*e .it- Adju1tab+e T-roat H&'I
Accordi*/ to t-e Aut-or #P Ge*e A1-+e &(D() t-e US pate*t ;Scrap S-ear
Mac-i*e .it- Adju1tab+e T-roat< A 1crap 1-ear mac-i*e compri1e1 o, a
compre11io* bo@6 a*d a* i*de@i*/ ram a*d a ram -ead mou*ted t-ereo* ,or
i*creme*ta++ ad>a*ci*/ t-e +o/ i*to t-e t-roat o, t-e 1-ear6 .-ereb i*creme*t1 o,
t-e +o/ are 1-eared o,,$ Arra*/eme*t1 are pro>ided ,or adju1ti*/ t-e .idt- o, t-e ram
-ead i* accorda*ce .it- t-e .idt- o, t-e compre11io* bo@ a*d 1-ear t-roat6
.-ereb t-e ma@imum dime*1io* o, t-e 1-eared 1crap ca* be co*tro++ab+ adju1ted i*
o*e pa11 t-rou/- t-e mac-i*e$
T-i1 i*>e*tio* re+ate1 to 1crap 1-ear mac-i*e1 a*d6 more particu+ar+6 to a *o>e+
a*d -i/-+4e,,ecti>e 1crap 1-ear mac-i*e .-erei* t-e mac-i*e ca* be
co*tro++ab+ adju1ted i* o*e pa11 t-rou/- t-e mac-i*e$ Scrap meta+ i1 di>ided i*to
,errou1 a*d *o*,errou1 cate/orie1 a*d .it-i* eac- cate/or i1 1o+d b
dime*1io*$ For e@amp+e 1crap -a>i*/ ma@imum dime*1io* o, t-ree ,eet6 ,our ,eet
or ,i>e ,eet i1 1o+d b t-e 1crap proce11or6 depe*di*/ o* t-e reCuireme*t1 o, t-e
1me+ter or ot-er cu1tomer ,or t-e 1crap meta+$ I, t-e cu1tomer .i++ accept 1crap
-a>i*/ a ma@imum dime*1io* o, ,i>e ,eet6 t-e 1crap proce11or .i++ .i1- to 1e++ ,i>e
,oot 1crap t-a* 1ma++er 1crap$
:$7 Scrap Materia+ S-reddi*/ a*d Compre11i*/ Apparatu1 a*d S1tem H&'I
Accordi*/ to t-e aut-or #0ame1 L$Le.i16 0r et a+6 :''E) ;Scrap Materia+
S-reddi*/ a*d Compre11i*/ Apparatu1 a*d S1tem< t-e US pate*t 1a16 A 1crap
materia+ recc+i*/ apparatu1 i*c+ude1 a ,eeder6 a 1-redder a*d a 1eparator6 t-e
,eeder a*d t-e 1-redder mutua++ coup+ed6 a*d t-e 1-redder a*d 1eparator
mutua++ coup+ed$ T-e ,eeder i*c+ude1 a mea*1 ,or ad>a*ci*/ t-e 1crap materia+
to t-e 1-redder$ T-e 1-redder i*c+ude1 a rotor -a>i*/ a p+ura+it o, cutti*/
mea*16 t-e rotor mec-a*ica++ rotated to reduce t-e 1crap materia+$ T-e 1eparator
1eparate1 t-e reduced 1crap materia+ b ,ractio*a+ compo1itio*$ T-e recc+i*/
apparatu1 ma be part o, a 11tem ,urt-er i*corporati*/ additio*a+ compo*e*t16
1uc- a1 co*>eor1 a*dMor du1t e@tractio* de>ice1$ T-e recc+i*/ apparatu1 ma
7
be ,urt-er adapted 1o a1 to be a tra*1portab+e 11tem6 t-ereb a++o.i*/ 1uc-
11tem to be re+ocated at or *ear 1crap materia+ 1toc=pi+e +ocatio*1$
I* o*e a1pect o, t-e di1c+o1ed embodime*t16 a 1crap materia+ recc+i*/
apparatu1 compri1e1 a ,eeder6 a 1-redder a*d a 1eparator6 t-e ,eeder a*d t-e
1-redder mutua++ coup+ed a*d t-e 1-redder a*d 1eparator mutua++ coup+ed$ T-e
,eeder compri1e1 a mea*1 o, compre11i*/ a Cua+it o, 1crap materia+ a*d mea*1 ,or
ad>a*ci*/ t-e 1crap materia+ to t-e 1-redder$ T-e 1-redder compri1e1 a rotor -a>i*/
a p+ura+it o, cutti*/ mea*16 1uc- a1 teet-6 =*i>e16 or -ammer16 .-erei* t-e rotor
mec-a*ica++ rotate1 to reduce t-e 1crap materia+$ T-e 1eparator 1ort1 t-e reduced
1crap materia+ b ,ractio*a+ compo1itio*$
:$8 Creatio* o, Faci+itie1 ,or e,,ecti>e ma*a/eme*t o, 1crap at rai+.a
u*it1H&&I
Accordi*/ to t-e E+ectro*ic 1ource ;Creatio* o, Faci+itie1 ,or e,,ecti>e
ma*a/eme*t o, 1crap at rai+.a u*it1< 1a16 a++ rai+.a u*it1 i*>o+>ed i* t-e
mai*te*a*ce o, i*,ra1tructure /e*erate 1crap$ T-i1 1crap ca* be c+a11i,ied i*to t-e
,o++o.i*/ cate/orie1
Recc+ab+e ,errou1 meta+
Recc+ab+e *o*4,errou1 meta+
Recc+ab+e p+a1tic M po+mer
Recc+ab+e /+a11
No*4recc+ab+e rubbi1-
T-e 1crap /e*eratio* a*d i*adeCuate 11tem o, remo>a+ re1u+t1 i* creatio*
o, 1toc=pi+e1 o, u*.a*ted materia+$ O*e t-e major ,actor1 .-ic- -i*der1 t-e
rapid remo>a+ o, 1crap i1 t-e co1t o, tra*1portatio* .-ic- i1 t-e 1ame ,or a /ood
or bad materia+$ Compou*di*/ t-e prob+em i1 t-e ,act t-at 1crap i1 *e>er
-omo/e*ou16 .-ic- cau1e1 i*crea1e i* bu+= ma=i*/ t-e co1t o, tra*1port e>e*
/reater
For better ma*a/eme*t o, 1crap t-e ,o++o.i*/ *eed1 to be atte*ded
8
T-e co1t o, tra*1port *eed1 to be reduced
T-e 1crap 1-ou+d be proce11ed partia++ to create a more de1irab+e6 ea1i+
tra*1portab+e a*d co*>e*ie*t+ recc+ab+e product$
T-e *o*4recc+ab+e rubbi1- *eed1 to be di1po1ed o, at t-e rai+.a
premi1e1 #t-i1 i1 a+1o t-e reCuireme*t o, t-e +a. u*der EPA4E8) t-i1 i1
po11ib+e b i*ci*erati*/ t-e 1ame a*d di1po1i*/ o, re1u+ti*/ 1oot i*
+a*d,i++1 a1 permitted$
For t-e recc+ab+e materia+ proce11i*/ ,aci+itie1 *eed to be created at t-e
co*>e*ie*t +ocatio*1 #o+d .or=1-op1 i* t-e >ici*it ma be idea+) ,or i*itia+
proce11i*/$ T-i1 .i++ i*c+ude
Compre11or1 M pu+>eri1er1
Materia+ 1orter M .a1-i*/ 11tem1
Me+ti*/ a*d ca1ti*/ proce11 11tem1
T-i1 .i++ be reCuired ,or eac- tpe o, recc+ab+e materia+$ A de1irab+e e*d
product .ou+d be bi++et1 o, t-e ra. materia+6 .-ic- ca* be t-e* tra*1ported ea1i+ ,or
,urt-er proce11i*/$ Mo1t o, t-e o+d mec-a*ica+ .or=1-op1 o, t-e I*dia*
Rai+.a1 -a>e ,ou*drie1$ T-e1e ca* be co*>erted to ,orm recc+i*/ ,aci+itie1 ,or
1crap ma*a/eme*t$
9
CHAPTER 5
CURRENT PRACTICE OF SCRAP REMO3AL AND STORAGE
IN 3ISHAL PRECISION PRODUCTS P3T LTD
5$& Curre*t Practice o, Scrap Remo>a+ a*d Stora/e
T-e Fi/ 5$& 1-o.1 t-e 1crap +i*/ o* t-e ,+oor o, t-e i*du1tr .-ere
.-ic- t-e 1tud .a1 co*ducted to do t-e de1i/*$ A1 .e ca* 1ee i* t-e
picture t-e 1crap remai*1 1cattered a*d itF1 a++ o>er t-e ,+oor *ot ju1t i* t-e
tra .-ere t-e 1crap 1-ou+d be +i*/$
Fi/ 5$& Scrap +i*/ o* 1-op ,+oor
T-e 1crap +i*/ o* t-e ,+oor i1 c+ea*ed u1i*/ t-e ma/*et 1-o.* be+o. i*
Fi/$ 5$:$ !ut t-i1 i1 *ot do*e >er ,reCue*t+$ T-e c+ea*i*/ i1 do*e o*+ .-e* t-e
.or=er ca**ot .or= o* t-e 1-op ,+oor$ So a1 .e ca* 1ee t-e 1crap /et1 pi+ed up
o* t-e 1-op ,+oor .-ic- cau1e1 1i/*i,ica*t di,,icu+t ,or t-e .or=er to per,orm
t-eir job$ T-e 1crap piece1 cou+d /et pric=ed i* t-e +e/1 o, t-e .or=er$ T-i1 ca*
cau1e 1eriou1 -ea+t- a*d 1a,et i11ue i* t-e .or=i*/ e*>iro*me*t$ T-e Fi/ 5$:
1-o.1 t-e er/o*omica++ de1i/*ed ma/*etic co++ector to co++ect t-e 1crap1 ,rom
t-e 1-op ,+oor$ T-i1 i1 -o. t-e remo>e t-e 1crap1 i* a 1ma++ 1ca+e .a$ T-at i16
10
.-i+e .or=i*/ i, 1ome 1crap1 come o* t-e ,+oor .-ere t-e .or=er i1 1ta*di*/
t-e remo>e t-e 1crap u1i*/ t-e abo>e 1-o.* 1crap co++ector$
Fi/ 5$: Ma/*et ,or remo>i*/ Scrap1
T-e ma/*et i1 =ept o* a* iro* tra$ T-e* t-e tra /et1 ma/*eti1ed$ T-e
ma/*eti1ed tra i1 ro++ed o>er t-e 1crap1 1o t-at t-e 1crap1 .i++ /et 1tic= to t-e
bottom o, t-e tra$ T-e* .-e* t-e 1crap *eed1 to be re+ea1ed t-e* t-e ma/*et i1
,+ipped up .ard1 1o t-at t-e iro* tra .i++ /et dema/*eti1ed a*d t-e 1crap .i++ be
re+ea1ed$ Scrap1 ,rom di,,ere*t mac-i*e1 co++ected i* a co*tai*er$
Fi/$ 5$5 Scrap Stora/e
11
T-e Fi/$ 5$5 1-o.1 t-e room .-ere .-ic- t-e 1crap i1 1tored$ T-e 1crap i1
1tored a*d retrie>ed ,rom t-e room i* a* u*or/a*iBed ma**er$ T-i1 cau1e1 e@tra
e,,ort a*d ma* po.er i* bot- t-e 1crap 1tora/e a*d remo>a+$
Fi/ 5$9 Tra ,or carri*/ Scrap
T-e 1crap i1 1tored i* a room .it- +e*/t- 8 meter6 .idt- 5 meter a*d
-ei/-t 5 meter$ T-e tra i1 u1ed to carr t-e 1crap$ T-e Fi/ 5$9 1-o.1 t-e 1crap
=ept i* t-e tr ,or mo>i*/ it to t-e 1crap 1tora/e room$ A-e* t-e 1crap i1 ,u++ i*
t-e tra t-e .ei/-t o, t-e 1crap i1 appro@imate+ :7=/$ I* t-e room t-e -ei/-t o,
t-e 1crap /oe1 up to &$7 meter$ O* a dai+ ba1i1 : to 9 tra1 o, 1crap are remo>ed
,rom t-e 1-op ,+oor$ T-e time ta=e* to remo>e 1crap1 ,rom t-e ,+oor i1 &$7 to :
-our1 o* a dai+ ba1i1$
12
CHAPTER 9
DESIGN6 FA!RICATION AND TESTING OF THE MACHINE
9$ Some T-eor o, Hdrau+ic1 a*d P*eumatic1 H7I
A detai+ed 1tud .a1 co*ducted to do t-e de1i/* o, t-e -drau+ic1$ !e,ore
ma=i*/ t-e circuit6 t-e t-eor o, -drau+ic1 .a1 re1earc-ed a*d 1tudied$
Fi/ 9$& Picture t-at demo*1trate1 Pa1ca+F1 La.
9$& Pa1ca+F1 La.
Pa1ca+F1 +a. 1tate1 t-at .-e* a co*,i*ed ,+uid i1 p+aced u*der pre11ure6 t-e
pre11ure i1 tra*1mitted eCua++ i* a++ directio*1 a*d o* a++ ,ace1 o, t-e co*tai*er$
T-i1 i1 t-e pri*cip+e u1ed to e@te*d t-e ram o* a -drau+ic c+i*der$ ! app+i*/
a ,orce to mo>e t-e pi1to* o* o*e e*d6 t-e pi1to* o* t-e ot-er e*d .i++ mo>e t-e
1ame di1ta*ce .it- 1ame amou*t o, ,orce$ Fi/ 9$& 1-o.* abo>e 1-o.1 a*
i++u1tratio* o, t-e abo>e t-eor$
9$: Hdrau+ic ;Le>era/e<
T-e Fi/ 9$: ,or e@p+ai*i*/ t-e -drau+ic +e>era/e i1 1-o.* be+o.$ T-e
+e>era/e .e /et .-e* .e i*crea1e t-e area i1 e@p+ai*ed i* detai+ a,ter t-e ,i/ure$
13
Fi/ 9$: Dia/ram ,or e@p+ai*i*/ ;Hdrau+ic Le>era/e<
Ae ca* i*crea1e t-e mec-a*ica+ ad>a*ta/e to +i,t a -ea>ier +oad$ T-i1 i1
t-e pri*cip+e t-at a++o.1 ou to jac= up a >er -ea> object .-i+e e@erti*/ a
1ma++ amou*t o, ,orce o* t-e -a*d+e o, a -drau+ic jac=$ T-e a*imated
i++u1tratio* 1-o.1 t-at & +b$ o, ,orce e@erted o* a & 1C$ i*$ pi1to*6 mo>ed &' i*$
.i++ +i,t &' +b1$ a di1ta*ce o, & i*$ .it- a &' 1C$ i*$ pi1to* o* t-e NP+aN butto* i*
t-e i++u1tratio* to 1ee a demo*1tratio*$ T-e +ar/er pi1to* .i++ mo>e a 1-orter
di1ta*ce6 but pro>ide1 t-e mec-a*ica+ ad>a*ta/e to +i,t a muc- -ea>ier +oad$ T-e
mec-a*ica+ .or=,orce ad>a*ta/e i* -drau+ic1 ca* be t-ou/-t o, a1 +e>era/e6 but
it i1 -drau+ic +e>era/e$
9$5 !a1ic Hdrau+ic S1tem
A+t-ou/- -drau+ic circuit +aout1 ma >ar 1i/*i,ica*t+ i* di,,ere*t
app+icatio*16 ma* o, t-e compo*e*t1 are 1imi+ar i* de1i/* or ,u*ctio*$ T-e
pri*cip+e be-i*d mo1t -drau+ic 11tem1 i1 1imi+ar to t-at o, t-e ba1ic -drau+ic
jac=$ Oi+ ,rom t-e re1er>oir i1 dra.* pa1t a c-ec= ba++ i*to t-e pi1to* tpe pump
duri*/ t-e pi1to*N1 up41tro=e$ A-e* t-e pi1to* i* t-e pump i1 pu1-ed do.*.ard6
oi+ .i++ be directed pa1t a 1eco*d c-ec= ba++ i*to t-e c+i*der$ A1 t-e pump i1
actuated up a*d do.*6 t-e i*comi*/ oi+ .i++ cau1e t-e c+i*der ram to e@te*d$
T-e +i,t c+i*der .i++ -o+d it1 e@te*ded po1itio* becau1e t-e c-ec= ba++ i1 bei*/
1eated b t-e pre11ure a/ai*1t it ,rom t-e +oad 1ide o, t-e c+i*der$ !ecau1e t-e
pump di1p+aceme*t i1 u1ua++ muc- 1ma++er t-a* t-e c+i*der6 eac- 1tro=e o, t-e
14
pump .i++ mo>e t-e c+i*der a >er 1ma++ amou*t$ I, t-e c+i*der i1 reCuired to
mo>e at a ,a1ter rate6 t-e 1ur,ace area o, t-e pump pi1to* mu1t be i*crea1ed
a*dMor t-e rate .-ic- t-e pump i1 actuated mu1t be i*crea1ed$ Oi+ ,+o. /i>e1 t-e
c+i*der ram it1 1peed o, mo>eme*t a*d oi+ pre11ure i1 t-e .or= ,orce t-at +i,t1
t-e +oad$
Fi/ 9$5 !a1ic Hdrau+ic S1tem
9$9 Re1er>oir
Here i1 a* e@amp+e o, a re1er>oir6 o*e o, t-e ,our ba1ic reCuireme*t1 to
ma=e a -drau+ic 11tem$ T-i1 particu+ar re1er>oir i1 made o, mou+ded p+a1tic
a*d i1 ,rom a Gree*1 ma1ter ridi*/ mo.er$
Fi/ 9$9 Re1er>oir
Fi/ 9$9 Re1er>oir
15
9$7 Pump
Ae ca* impro>e t-e e,,icie*c a*d i*crea1e t-e >er1ati+it o, a ba1ic circuit b
addi*/ 1ome more 1op-i1ticated compo*e*t1 a*d c-a*/i*/ t-e circuit +aout$ !
i*corporati*/ a /ear pump i* p+ace o, a -a*d pi1to* pump6 .e i*crea1e oi+ ,+o.
to t-e c+i*der .-ic- .i++ i*crea1e t-e actuatio* rate o, t-e ram$ T-e ima/e to t-e
ri/-t 1-o.1 a cuta.a >ie. o, a t-ree 1ectio* /ear pump$ Ae ca* 1ee t-e /ear
1et1 ,or a++ t-ree 1ectio*1 a*d t-e i*put #dri>e) 1-a,t$ A /ear pump i1 a po1iti>e
di1p+aceme*t pump6 mea*i*/ t-at .-e*e>er t-e pump i1 tur*i*/ t-e pump mu1t
pump oi+$ I, pump ,+o. i1 tota++ b+oc=ed6 1udde* ,ai+ure o, t-e pump or ot-er
compo*e*t .i++ occur$ A1 t-e /ear1 i* t-e pump rotate6 1uctio* i1 created at t-e
i*+et port o, t-e pump$ T-e ,+uid i1 dra.* i* to t-e pump a*d i1 carried i* t-e
1pace1 bet.ee* t-e /ear teet- to t-e di1c-ar/e port o, t-e pump$ At t-e di1c-ar/e
1ide o, t-e pump t-e /ear teet- me1- to/et-er a*d t-e oi+ i1 di1c-ar/ed ,rom t-e
pump$ Note t-at t-e pump create1 ,+o.$ T-e pump6 b it1e+,6 doe1 *ot create
pre11ure$ Pre11ure re1u+t1 o*+ .-e* t-ere i1 re1i1ta*ce to ,+o.$ "ou ca**ot -a>e
pre11ure .it-out ,+o. #or pote*tia+ ,+o.)$
Fi/ 9$7 Pump
16
9$8 Co*tro+ 3a+>e
T-e ,+o. ,rom t-e pump to t-e c+i*der i1 co*tro++ed b a 1+idi*/ 1poo+ >a+>e
.-ic- ca* be actuated a -a*d or ,oot operated +e>er or a* e+ectric 1o+e*oid$ T-e
ima/e to t-e ri/-t 1-o.1 a cuta.a o, a* actua+ -drau+ic co*tro+ >a+>e$ T-e
>a+>e 1-o.* i* t-e i++u1tratio* i1 ope* ce*tre >a+>e6 mea*i*/ t-at t-e oi+ ,+o. i1
retur*ed to t-e re1er>oir .-e* t-e >a+>e i1 i* t-e *eutra+ po1itio*$ T-e 1poo+
>a+>e -a1 t-e capabi+it to direct ,+uid ,+o. to eit-er e*d o, t-e actuator$ A1 t-e
1poo+ i1 mo>ed6 ,+uid i1 redirected to o*e e*d or t-e ot-er o, t-e actuator6 .-i+e
,+uid bei*/ pu1-ed out t-e ot-er e*d o, t-e actuator i1 directed bac= to re1er>oir
t-rou/- t-e >a+>e$
Fi/ 9$8 Co*tro+ 3a+>e
17
T-e de1i/* i1 do*e i* So+id Aor=1 :'&5$ T-e ,abricatio* o, t-e mac-i*e i1
e@ecuted i* t-e Aor=1-op$ T-e te1ti*/ o, t-e mac-i*e .a1 carried out i* t-e
Hdrau+ic1 Lab$
9$D Hdrau+ic Pre11 C+i*der
T-e -drau+ic c+i*der1 are t-e mai* part i* t-e ca1e o, t-e 1crap bai+i*/
pre11$ T-e mai* -drau+ic c+i*der carrie1 t-e bai+i*/ pre11 too+ ,or bai+i*/ t-e
1crap$ I* t-i1 -drau+ic c+i*der t-e pi1to* ma=e1 o*e ,or.ard a*d retract motio* to
bai+ or compre11 t-e 1crap o, mo1t o, t-e 1crap tpe1 ,rom di,,ere*t mac-i*i*/
proce11 .-ic- are di,,ere*t tpe o, materia+1
!arr+e14Tube 1eam+e11 -o*ed barre+1 #1tee+Mbra11Ma+umi*ium) to a micro4
,i*i1- pro>ide +o*/ pi1to* 1ea+ +i,e a*d pre>e*t ,ai+ure o, t-e c+i*der$
Pi1to* Rod4Hi/- 1tre*/t- 1tee+ pi1to* rod i1 preci1io* /rou*d a*d -ard
c-rome p+ated a*d re/ri*d1 to e*1ure a*ti4corro1io* a*d ma@imum 1ea+
+i,e$ T-e rod materia+ i1 EN4E$
Pi1to*4Ca1t iro*
C+i*der !a1e4T-e e*d o, t-e c+i*der i1 preci1io* bo+ted t-e ba1e i1
t-readed G t-e* .e+di*/ .it- utmo1t accurac a*d preci1io*$
9$D$& Die Ca1ti*/ C+i*der
T-e1e c+i*der1 are t-e mai* part o, t-e 1crap bai+i*/ pre11 arra*/eme*t
.-ic- carr t-e die 1ectio* .-ic- are u1ed to compact t-e i*comi*/ 1crap1$ Eac-
c+i*der -a1 -a+, 1ectio* o, a cubic die arra*/eme*t ma=e1 co*tact a*d ,orm1 a
cubic die ca>it i* .-ic- t-e 1crap1 are ,eed to bai+ it i*to cube1$ T-e1e c+i*der1
-a>e a do>e tai+ ope*i*/ i* t-e c+o1ed 1ide ,aci+itate t-eir 1+idi*/ motio* o>er a
do>e tai+ 1add+e to a>oid .ear a*d tear o, t-e ba1e o, t-e die ca>it 1ectio* .-i+e
t-e pi1to* ma=e1 ,or.ard a*d retractio* motio*$ T-e die ca>it 1ectio* -a1 1ome
-o+e1 i* t-e 1ide .a++1 to a++o. t-e air bet.ee* t-e 1crap1 .-i+e pre11i*/ or
bai+i*/$
18
9$E Hdrau+ic Co*tro+ S1tem1
T-e 1crap bai+i*/ pre11 arra*/eme*t -a1 t-ree c+i*der1 .-ic- are
operati*/ b t-e -drau+ic po.er a*d co*tro+ 11tem$ T-e are u1ed to re/u+ate a*d
direct t-e ,+o. o, ,+uid i* t-e re1pecti>e pipe +i*e1$ T-e -drau+ic co*tro+ 11tem
co*1i1t1 o, ,o++o.i*/6
Directio* co*tro+ >a+>e
SeCue*ce >a+>e1
Pre11ure re+ie, >a+>e
C-ec= >a+>e1
Oi+6 pump6 ta*= a*d oi+ ,i+ter1 etc$
9$( Directio* Co*tro+ 3a+>e
T-e directio*a+ co*tro+ >a+>e u1ed -ere i1 9M5 directio*a+ co*tro+ >a+>e$ I*
t-i1 >a+>e t-ere are 9 port1 a*d 5 di1ti*ct po1itio*1$ Oi+ e*ter1 i*to t-e >a+>e
t-rou/- ,i+ter a*d pump$ So+e*oid actuated6 1pri*/ retur* mec-a*i1m i1 u1ed i*
t-i1 directio* co*tro+ >a+>e$ It i1 u1ed to co*tro+ t-e directio* o, ,+o. o, oi+$
9$&' Ot-er Part1
9$&'$& Pre11ure Re+ie, 3a+>e
Pre11ure re+ie, >a+>e ot-er.i1e ca++ed pre11ure +imiti*/ >a+>e .-ic- i1
+ocated bet.ee* pump a*d actuator$ A re+ie, >a+>e +imit1 t-e ma@imum pre11ure t-at
ca* be app+ied to t-e part o, t-e 11tem .-ic- it i1 co**ected$ It a+1o protect1 a 11tem
,rom e@ce11i>e ,+uid pre11ure o>er a*d abo>e t-e de1i/* pre11ure +imit$ It i1 u1ed
.-ere t-e ,+o. rate a*d t-e 11tem pre11ure are +o.$
9$&'$: SeCue*ce 3a+>e
T-e 1eCue*ce >a+>e1 are t-e tpe o, pre11ure co*tro+ >a+>e .-ic- i1 u1ed to
co*tro+ t-e ,+uid ,+o. to e*1ure 1e>era+ operatio*1 i* a particu+ar order o, priorit
i* t-e 11tem$ It a++o.1 t-e ,+uid to operate ,ir1t p-a1e .-e* t-e 11tem i*+et pre11ure
i1 .it-i* pre1et >a+ue pre11ure6 i, t-e pre11ure e@ceed1 t-e pre41et >a+ue t-e ,+o. i1
di>erted to 1eco*d p-a1e$
9$&'$5 C-ec= 3a+>e1
T-e c-ec= >a+>e i1 o*e tpe o, directio*a+ co*tro+ >a+>e$ It i1 u1ed to
a++o. ,ree ,+o. i* o*+ o*e directio* a*d to pre>e*t a* ,+o. i* t-e ot-er
19
directio*$ It b+oc=1 t-e re>er1e ,+o. o, t-e ,+uid6 1o it i1 ot-er.i1e ca++ed *o*4
retur* >a+>e1$
9$&'$9 Oi+ Pump1 a*d Oi+ Fi+ter1
T-e -drau+ic oi+ u1ed -ere i1 -droi+ or a* ot-er mi*era+ oi+ or a*
-drau+ic oi+1$ T-e oi+ ,i+ter1 u1ed -ere i1 to remo>e t-e impuritie1 ,rom t-e oi+$
9$&& Hdrau+ic Circuit ,or t-e Scrap Compre11i*/ Mac-i*eH&:I
T-e Fi/ 9$D 1-o.* be+o. i1 a 1imp+e -drau+ic circuit dia/ram ,or a 1crap
compre11i*/ mac-i*e$ T-e co**ectio* i1 ta=e* ,rom t-e pump a*d co**ected to
t-e co*tro+ >a+>e$ T-e pump i1 co**ected to t-e re1er>oir t-rou/- a ,i+ter .-ic-
,i+ter1 t-e du1t partic+e1 comi*/ out ,rom t-e circuit$
Fi/ 9$D Hdrau+ic Circuit ,or Scrap Compre11i*/ Mac-i*e
T-e* ,rom co*tro+ >a+>e t.o co**ectio*1 i1 ta=e* a*d co**ected to t-e c+i*der$
O*e +i*e ,rom t-e co*tro+ >a+>e i1 1imp+ put i* t-e re1er>oir ta*=$ So t-e ,+uid i1
pumped to t-e co*tro+ >a+>e6 b tur*i*/ retract6 t-e ,+uid co*tro+ to t-e ,ir1t port
i1 re/u+ated$ T-e* t-e ,+uid .i++ pu1- t-e c+i*der to t-e ot-er e*d$ A-e* retract
i1 re+ea1ed t-e ,+uid .i++ +o. bac= to t-e re1er>oir t-rou/- t-e ta*= +i*e$
20
9$&: P*eumatic Co*tro+ S1tem1
T-i1 11tem i*c+ude1 >ariou1 DC3F16 FRL u*it6 Mu,,+er etc$ T-e are u1ed
to re/u+ate a*d direct t-e ,+o. o, air i* t-e re1pecti>e pipe +i*e1$ T-e p*eumatic
11tem u1ed ,or t-e ejector o*+$
Directio*a+ co*tro+ >a+>e
FRL u*it
Mu,,+er etc$
9$&:$& Directio* Co*tro+ 3a+>e
T-e directio* co*tro+ >a+>e u1ed -ere i1 7M: directio*a+ co*tro+ >a+>e$ I* t-i1
>a+>e t-ere are 7 port1 a*d 5 di1ti*ct po1itio*1$ So+e*oid actuated6 1pri*/ retur*
mec-a*i1m i1 u1ed i* t-i1 directio*a+ co*tro+ >a+>e$ It i1 u1ed to co*tro+ t-e directio*
o, ,+o. o, air$
9$&:$: Mu,,+er
T-e mu,,+er i1 u1ed to co*tro+ t-e *oi1e cau1ed b t-e air 1tream ,+o.i*/ i*to
t-e atmo1p-ere$
9$&:$5 FRL U*it
It mea*1 ,i+ter6 re/u+ator a*d +ubricator u*it$ Fi+ter i1 u1ed to remo>e
impuritie1 i* t-e compre11ed airJ re/u+ator i1 u1ed to re/u+ate t-e pre11ure o, t-e
i*comi*/ air6 +ubricator mi@ t-e oi+ .it- t-e air$
T-e c+i*der A a*d ! i1 co**ected to t-e A a*d ! port o, Directio*
Co*tro+ 3a+>e #DC3)$ T-e P port o, DC3 i1 co**ected to t-e Pump a*d T port o,
DC3 i1 co**ected to t-e ta*= +i*e$ T-e po.er pac= co*1i1t1 o, a Motor6 Pump a*d a*
i*ter*a+ re+ie, 3a+>e$ T-e Pump i1 co**ected to a E@ter*a+ Pre11ure Re+ie, 3a+>e6
Pre11ure Gau/e a*d to t-e P port o, DC3 i* 1erie1$ To operate t-e Mac-i*e t-e
pump i1 1.itc-ed o* a*d t-e +e>er o, t-e DC3 i1 tur*ed$ T-e ,+uid ,rom t-e pump i1
pumped to Port A a*d t-e c+i*der .i++ 1tart mo>i*/ ,or.ard a*d 1tart compre11i*/
1crap$
9$&5 Te1ti*/ 1imi+ar Circuit i* P*eumatic1
!e,ore mo>i*/ i*to ,abricatio* a*d ,urt-er a*a+1i1 o, t-e eCuipme*t a
1imi+ar circuit .a1 te1ted i* p*eumatic1 ju1t to u*der1ta*d t-e t-eor a*d
21
.or=i*/ o, t-e 11tem$ T-e Fi/ 9$E 1-o.* be+o. 1-o.1 t-e te1ti*/ o, t-e
p*eumatic circuit i* t-e P*eumatic Lab$
Fi/ 9$E Te1ti*/ t-e Circuit i* P*eumatic Lab
T-e circuit i1 te1ted a*d t-e co**ectio*1 are ,i/ured out$ It /a>e a c+ear
idea o* t-e ma=i*/ o, circuit a1 .e++ a1 t-e .or=i*/ o, DC36 FC36 PR36 a*d
C+i*der$
Fi/ 9$( P*eumatic Circuit
22
From t-e Fi/ 9$( .e ca* 1ee t-e i*put P +i*e a co**ectio* i1 ta=e* a*d
co**ected to t-e DC 3a+>e a*d F+o. Co*tro+ 3a+>e a*d ,rom t-ere A a*d ! +i*e
i1 co**ected to t-e C+i*der$ A Pre11ure re+ie, >a+>e i1 co**ected to t-e output
,rom ! port o, t-e c+i*der bac= to t-e compre11or$
9$&9 Ae+ded 0oi*t Tpe1 H8I
T-e America* Ae+di*/ Societ de,i*e1 a joi*t a1
;t-e ma**er i* .-ic- materia+1 ,it to/et-er$< A1 1-o.* i* Fi/ 9$&' t-ere are ,i>e
ba1ic tpe1 o, .e+d joi*t1
O !utt joi*t
O T4joi*t
O Lap joi*t
O Cor*er joi*t
O Ed/e joi*t
I* t-e mac-i*e ,abricated6 cor*er joi*t1 are t-e joi*t1 are do*e a++ a+o*/$ Fi/ 9$&'
1-o.1 di,,ere*t tpe1 o, .e+ded joi*t1$
Fi/ 9$&' Di,,ere*t tpe1 o, .e+ded 0oi*t1
I* t-e mac-i*e ,abricated ,i++et .e+d i1 t-e ma@imum u1ed o*e$ T-e
Fi/ 9$&& 1-o.* be+o. i1 t-e dia/ram ,or a ,i++et .e+d$
Fi/ 9$&& Fi++et Ae+d
23
I* t-i1 tpe o, .e+d t.o p+ate1 are -e+d to/et-er a1 1-o.* i* t-e ,i/ure
a*d .e+ded$ T-e ca+cu+atio* ,or te1ti*/ t-e 1u1tai*abi+it o, t-e ,i++et .e+d i* t-e
mac-i*e come1 i* t-e ,o++o.i*/ 1ectio*$
9$&7 S-ie+ded Meta+ Arc Ae+di*/ H:I
S-ie+ded Meta+ Arc Ae+di*/ i1 u1ed ,or .e+di*/ t-e mac-i*e$ I* t-at a*
e+ectrode i1 u1ed to ma=e t-e .e+d$ T-e mac-i*e i1 co**ected to t-e AC 1upp+$
It -a1 /ot a co*tro+ pa*e+ to co*tro+ t-e po.er$ T-e .or= cab+e i1 touc-ed .it-
t-e .or= piece$ T-e e+ectrode -o+der -o+d1 t-e e+ectrode$ A-e* t-e e+ectrode
touc-e1 t-e part to be .e+ded Arc .i++ be produced .-ic- .i++ me+t t-e e+ectrode
to ,orm 1o+idi,ied 1+a/ a*d .e+d meta+$
Fi/ 9$&: S-ie+ded Meta+ Arc Ae+di*/
T-e Fi/ 9$&: 1-o.1 a tpica+ S-ie+ded Meta+ Arc Ae+di*/$ T-e 1eco*d part o,
t-e picture 1-o.1 .-at -appe*1 .-e* t-e e+ectrode i1 touc-ed to t-e ba1e meta+$
A 1-ie+di*/ /a1 i1 produced to pre>e*t o@idatio*$ T-e e+ectrode me+t1 a*d t-e
.e+d meta+ a*d 1o+idi,ied 1+a/ i1 produced$
9$&8 Force ReCuired ,or Compre11io*
From +iterature it i1 ,ou*d t-at t-e ,orce .-ic- i1 app+ied ,or a 1crap
compre11or i1 &:7 To*1 ,or t-e compre11i*/ room 1iBe o, &:'' D'' 8''mm$
T-e ,orce reCuired ,or t-e compre11i*/ 1crap i* t-e *e. mac-i*e o, compre11i*/
room 1iBe &E' &E' &E'mm$
24
=
&:7'''M&:'' D'' P F
&
M&E' &E'
F
&
P 9E:&$9:=/
F
&
P9$E:&To*1
C+i*der diameter reCuired P 9' mm
Stro=e Le*/t- P :''mm
Pre11ure P 7' bar
Pre11ure Co*tro+ 3a+>e #Re+ie, 3a+>e) P D7bar
25
4 #&)
#F& P &:7''' =/ HDI)
9$&D De1i/* Co*cept De>e+oped
T-e Fi/ 9$&5 1-o.* be+o. i1 t-e co*cept de>e+oped a1 per t-e 1u//e1tio*
,rom t-e compa* .-ere t-e 1tud .a1 co*ducted$ T-e co*cept i1 to compre11 t-e
1crap 1trai/-t a.a ,rom t-e +at-e6 dri++i*/6 mi++i*/ mac-i*e a*d compre11 a*d
ma=e it i*to b+oc=1$
Fi/ 9$&5 I*itia+ Co*cept o, t-e Scrap Compre11i*/ Mac-i*e
T-e Fi/ 9$&5 i1 t-e i*itia+ co*cept de>e+oped$ T-e 1cre. co*>eor ta=e1 t-e
1crap ,rom t-e +at-e a*d de+i>er1 i*to t-e compre11io* bo@$ T-e* a -drau+ic
c+i*der i1 u1ed to compre11 t-e 1crap to a b+oc=$
9$&E Co1ti*/
Di,,ere*t co1t1 i*>o+>ed i* t-e 1crap ma*a/eme*t are6 o* a dai+ ba1i1 t.o
-e+per1 o, .a/e1 R1 8'''Mmo*t- #:7 .or=i*/ da1) .or= ,or : -our1$ A room o,
1iBe 8 meter +o*/6 5 meter .ide a*d 5 meter -ei/-t i1 dedicated ,or 1crap 1tora/e$
Stora/e Co1t 4 9''' INRMmo*t-
Ma*po.er Co1t 4 :9'' INRMmo*t-
26
Tota+ Co1t o, 1crap remo>a+ a*d 1tora/e i1 89'' INRMmo*t-$ T-i1 i1 t-e tota+
co1t be,ore i*1ta++i*/ t-e mac-i*e$
T-e co1t o, e+ectricit i* Tami+*adu ,or I*du1trie1 i1 E INRMu*it$ A & Hp
motor i1 D98 Aatt1$ A &''' Aatt1 motor .i++ co*1ume & U*it o, e+ectricit i*
o*e Hour$ So i, t-e po.er pac= -a1 /ot a motor o, &HP t-e* it .i++ co*1ume
'$D98 u*it1 o, E+ectricit .-ic- .i++ co1t 7$(8E INRM-our$ So t-e tota+ po.er
co*1umptio* co1t ,or a mo*t- i1 57E INR$ From t-e +iterature it i1 ,ou*d t-at t-e
compre11ibi+it ratio i1 7%&$ So t-e 1tora/e 1pace reCuired a,ter compre11i*/ t-e
.-o+e 1crap i1 o*e 7
t-
o, t-e curre*t 1pace$ So t-e co1t o, 1tora/e .i++ be E''
INR$ I, .e imp+eme*t t-e co*>eer ba1ed 1crap compre11or t-e* .e ca* a11ume t-e
*umber o, per1o* .or=i*/ ,or t.o -our1 ca* be reduced ,rom t.o to o*e$ So t-e
co1t o, ma*po.er .i++ become &:'' INR ,or a mo*t-$ So i, .e add t-e1e ,actor1
t-e* t-e tota+ co1t o, 1crap remo>a+ .i++ become :57E INRMmo*t-$ T-i1 i1 +e11 t-a*
t-e -a+, o, curre*t co1t$ T-e prototpe .i++ co1t &7''' INR e@c+udi*/ t-e po.er
pac= .-ic- co1t1 5'''' INR$ T-e co1t 1a>i*/1 per mo*t- a,ter t-e i*1ta++atio* o,
t-e 1crap compre11or i1 9'9: INR$ So t-e mac-i*e .i++ !rea= E>e* i* && mo*t-1
,rom it1 i*1ta++atio*$
27
CHAPTER 7
7$ Fi*ite E+eme*t A*a+1i1 #FEA)
T-e Fi*ite E+eme*t A*a+1i1 i1 do*e b di>idi*/ t-e .-o+e mac-i*e to
1ma++ part1 b a proce11 ca++ed me1-i*/$ T-e* t-e 1ma++ e+eme*t1 .-ic- i1
tec-*ica++ ca++ed Fi*ite E+eme*t1 i1 a*a+1ed 1eparate+ u1i*/ t-e 1o,t.are a*d
t-e re1u+t obtai*ed b combi*i*/ t-e re1u+t1 o, t-e 1ma++ e+eme*t1$ T-i1
met-odo+o/ i1 u1ed to obtai* more accurate re1u+t1 ,or t-e a*a+1i1$
7$& De1i/* ,or Fabricatio* a*d FEA A*a+1i1
T-e 1o+id mode+ i1 de>e+oped i* So+id Aor=1 :'&'$ T-e mode+ -a1 /ot a
1crap compre11io* bo@6 a p+ate to compre11 1crap6 t.o c-a**e+1 to -o+d t-e
ope*i*/ door a,ter compre11i*/ 1crap6 a c+i*der co**ected to t-e compre11i*/
p+ate$ T-e c+i*der i1 bo+ted to t-e ,rame b u1i*/ M&' !o+t1 a*d Nut1$
Fi/ 7$& So+id Mode+ o, t-e Scrap Compre11i*/ Mac-i*e
T-e mode+ ,or ,abricatio* i1 do*e i* So+id Aor=1 :'&'$ T-e Fi/ 7$&
1-o.* i1 t-e mode+ ,or ,abricatio* a*d a*a+1i1$ T-e pi1to* i1 co**ected to a
1Cuare p+ate .-ic- /oe1 -a+, .a o, t-e compre11i*/ c-amber$ So t-e 1crap i1
put i*to t-e c-amber b .eari*/ /+o>e1$ G+o>e1 -a>e to be .or* a1 it ca* pric=
o* bare -a*d1 cau1i*/ i*jurie1$
29
7$: So+id !od ,or FEA A*a+1i1
T-e 1o+id bod 1-o.* i* Fi/ 7$: i1 u1ed to do t-e FEA a*a+1i1$ I* t-i1
a*a+1i1 o*+ bod i1 co*1idered a*d t-e c+i*der i1 a>oided ,or co*>e*ie*ce o,
a*a+1i1$
Fi/ 7$: So+id bod ,or FEA
T-e FEA i1 do*e o* t-e 1o+id bod b ,i@i*/ t-e bottom o, t-e mac-i*e$ It i1
e>ide*t ,rom t-e Fi/ 7$: t-at t-e bottom i1 ,i@ed a*d i1 i*dicated b /ree*
arro.1 do.*.ard1$
Ma11 P :E$D8D =/
3o+ume P '$''5D57(E m
5
De*1it P DD'' =/Mm
5
Aei/-t P :E&$(&D N
7$5 Me1-i*/ ,or FEA
Fi/ 7$5 1-o.1 t-e me1-i*/$ Tria*/u+ar me1-i*/ i1 do*e ,or t-e FEA
a*a+1i1$ ! doi*/ tria*/u+ar me1-i*/ t-e 1o+id mode+ i1 di>ided i*to 1ma++
tria*/u+ar e+eme*t1$ T-e1e tria*/u+ar e+eme*t1 are t-e* a*a+1ed u1i*/ So+id
Aor=1 :'&'$
30
Fi/ 7$5 Tria*/u+ar me1-i*/ i1 do*e ,or doi*/ FEA
T-e materia+ u1ed ,or ma=i*/ t-e mode+ i1 A++o Stee+$ T-e "ie+d
Stre*/t- i1 8$:'9::eQ''E NMm
:
a*d Te*1i+e Stre*/t- i1 D$:5E:8eQ''E NMm
:
$ I* t-e
mode+ ,or a*a+1i1 t-e ,ace at t-e bottom i1 ,i@ed a*d a Pre11ure o, &7&:5 NMm
:
i1
app+ied o* t-e 7 i**er .a++1 a*d & compre11i*/ p+ate$ T-e me1- tpe i1 1o+id a*d
me1- Cua+it i1 ta=e* a1 Hi/-$ T-e tota+ *umber o, *ode1 i1 79EE a*d tota+ e+eme*t1
are :D7'$
7$9 >o* Mi1e1 Stre11
T-e >o* Mi1e1 1tre11 i1 ca+cu+ated u1i*/ So+id Aor=1 :'&'$ T-e Fi/ 7$9
1-o.* be+o. 1-o.1 t-e >o* Mi1e1 1tre11 di1tributio*$
Fi/ 7$9 >o* Mi1e1 Stre11
T-e mi*imum 1tre11 i1 &$'&5(5 NMm
:
o* 7&:8a*d t-e ma@imum 1tre11 i1
89::&( NMm
:
o* &D88 *ode1$ >o* Mi1e1 1tre11 a*a+1i1 -e+p1 to ,i*d t-e
31
ma@imum 1tre11 t-at t-e mac-i*e ca* .it- 1ta*d$ I* ot-er .ord1 t-e ma@imum
a++o.ab+e 1tre11 1-ou+d be be+o. t-e ma@imum >o* Mi1e1 1tre11$
7$7 De,ormatio* ,or t-e App+ied Load
T-e de,ormatio* i1 ,ou*d u1i*/ FEA a*a+1i1$ Mi*imum di1p+aceme*t i1
' mm o* &5E *ode1 a*d ma@imum di1p+aceme*t i1 '$''&:87DD mm o* &DD:
*ode1$
Fi/ 7$7 De,ormatio* ,or t-e App+ied Load
Fi/ 7$7 1-o.1 t-e de,ormatio* ,or t-e app+ied +oad$ From t-e abo>e
1-o.* dia/ram t-e di1p+aceme*t i1 ma@imum at t-e ce*tre o, t-e p+ate1$ T-e
a*a+1i1 i1 do*e b ,i@i*/ t-e bottom o, t-e p+ate a*d app+i*/ a pre11ure at t-e ,ace1
o, t-e p+ate1$
32
CHAPTER 8
8$& Fabricatio*
T-e ,abricatio* .a1 do*e i* t-e Lat-e a*d Ae+di*/ Aor=1-op1$ Te1ti*/
o, t-e mac-i*e .a1 do*e i* t-e Hdrau+ic1 Lab$ T-e po.er pac= i* t-e -drau+ic
+ab .a1 uti+i1ed ,or te1ti*/ t-e mac-i*e$ T-e Fi/ D$& 1-o.* be+o. i1 t-e
per1pecti>e6 top6 1ide a*d ,ro*t >ie. o, t-e mac-i*e$ T-e dime*1io*1 o, di,,ere*t
part1 are mar=ed i* t-e ,i/ure a*d a++ dime*1io*1 are i* ce*timetre$
Fi/ 8$& Detai+ed Dra.i*/1 o, t-e Mac-i*e
A++ t-e meta+ part1 .ere procured b /a1 cutti*/$ T-e c-a**e+ .a1 made b
mi++i*/ operatio*$ T-e bo@ ,or compre11i*/ 1crap .a1 made b .e+di*/ i* t-e
.or=1-op$ T-e de1i/* .a1 do*e i* 1uc- a .a t-at t-e mac-i*e ca* be
di1ma*t+ed i, reCuired to do a* ,urt-er adju1tme*t1 or mai*te*a*ce$
T-e mode+ ,or ,abricatio* i1 do*e i* So+id Aor=1 :'&'$ T-e Fi/ 8$& 1-o.* i1 t-e
mode+ ,or ,abricatio*$ It -a1 /ot a -drau+ic c+i*der .it- a pi1to*$ T-e pi1to* i1
co**ected to a 1Cuare p+ate .-ic- /oe1 -a+, .a o, t-e compre11i*/ c-amber$ So
t-e 1crap i1 put i*to t-e c-amber b .eari*/ /+o>e1$ G+o>e1 -a>e to be .or* a1 it
ca* pric= o* bare -a*d1 cau1i*/ i*jurie1$
33
8$: Te1ti*/ o, t-e ,abricated Scrap Compre11i*/ Mac-i*e
T-e Fi/ 8$: be+o. 1-o.1 t-e ,abricated Scrap Compre11i*/ Mac-i*e a*d it1
te1ti*/ i* t-e Hdrau+ic1 Lab$ T-e Scrap Materia+1 are co++ected ,rom t-e CNC
Lat-e a*d put it i*to t-e 1crap compre11io* c-amber$ T-e* -drau+ic1 i1 app+ied to
compre11 t-e 1crap$ T-e pre11ure /au/e .a1 1-o.i*/ a readi*/ o, 7'4
77 2/Mcm
:
.-i+e compre11i*/ t-e 1crap$ T-e 1crap i1 put i* t-e mac-i*e a*d
compre11ed b tur*i*/ t-e +ea>er o, DC 3a+>e$
Fi/ 8$: Te1ti*/ Scrap Compre11i*/ Mac-i*e
A,ter compre11i*/ more a*d more 1crap i1 put i* t-e c-amber a*d
compre11ed to ,orm t-e b+oc= o, compre11ed 1crap$ At +a1t .-e* t-e c-amber i1
34
,i++ed .it- t-e 1crap t-e e*d ope*i*/ i1 ope*ed b +i,ti*/ t-e p+ate t-rou/- t-e
c-a**e+1 a*d t-e compre11io* i1 ,urt-er /i>e* to pu1- out t-e 1crap out o, t-e
c-amber$
T-e compre11ed 1crap i1 1-o.* i* Fi/ 8$5$ T-e i*itia+ >o+ume o, t-e b+oc=
.a1 :&:': cm
5
a*d a,ter compre11i*/ t-e 1crap it .i++ become 7E5: cm
5
$ T-e
>o+ume o, t-e compre11ed 1crap i1 reduced b t-e ratio o, 5%&$
Fi/ 8$5 T-e Compre11ed Scrap
T.o buc=et o, t-e 1iBe 1-o.* i* t-e ,i/ure i1 compre11ed to ,orm t-e
1crap b+oc= .-ic- i1 i* m -a*d1$
35
CHAPTER 7
Co*c+u1io*
T-e Scrap Compre11i*/ Mac-i*e ,or 1ma++ 1ca+e i*du1trie1 i1 de>e+oped6
de1i/*ed6 ,abricated a*d te1ted$ T-e co1ti*/ o, t-e mac-i*e i1 ca+cu+ated a*d t-e
brea= e>e* period i1 determi*ed$ It .a1 ,ou*d t-at t-e brea= e>e* period o, t-e
mac-i*e i1 && mo*t-1$ T-e mac-i*e de1i/* a*d FEA a*a+1i1 i1 do*e i* So+id
Aor=1 :'&'$ A ,ati/ue a*a+1i1 a*d a*a+1i1 ,or .e+ded joi*t i1 a+1o ca+cu+ated$
A*d it .a1 deduced t-at t-e mac-i*e .i++ 1u1tai* t-e +oad app+ied$ T-e 1crap i1
compre11ed a*d t-e >o+ume o, t-e 1crap .i++ be compre11ed b t-e ratio o,
T-e detai+ed dra.i*/1 a*d picture1 o, t-e Scrap Compre11i*/ Mac-i*e are
docume*ted$ T-e i*itia+ >o+ume o, t-e b+oc= .a1 :&:': cm
5
a*d a,ter
compre11i*/ t-e 1crap it .i++ become 7E5: cm
5
$ T-e >o+ume o, t-e compre11ed 1crap
i1 reduced b t-e ratio o, 5%&$ T-i1 i1 ,or a+umi*ium 1crap$
36
REFERENCES
H&I Liu 0ia*@io*/6 Pe*/ 0u*tao6 "a*/ !a*/c-e*/6 Hou 0ie6 T-e Re1earc- o*
S-reddi*/ Mode+1 o, Li/-t Meta+ Scrap o, E*d4o,4+i,e 3e-ic+e1 a*d
Hou1e-o+d App+ia*ce16 IERI Procedia6 3o+$&6 :'&:6 Pa/e1 &984&79$
H:I Ma*u,acturi*/ Proce11 ,or E*/i*eeri*/ Materia+16 7
t-
Editio*6 2a+pa=jia*6
Sc-mid
H5I S 0a+a+udee*6 ;De1i/* o, Mac-i*e E+eme*t1<6 Mac-i*e De1i/* 4&6 9$&9:6
&$9:6 &$986 5$&7$
H9I S$ Dariu1 G*a*araj6 Scrap compre11io* mac-i*e14 o>er>ie.6 Natio*a+
Semi*ar o* Er/o*omic1 ,or E*-a*ced Producti>it6 Tami+*adu A/ricu+tura+
U*i>er1it6 Madurai6 I*dia6 #Feb$ &Et- G &(t- :'&5)
H7I Tec-*ica+ Trai*i*/ Ma*ua+ o* Hdrau+ic16TORO U*i>er1it6 USA$
H8I Tec-*ica+ Trai*i*/ Ma*ua+ o* Ae+d 0oi*t1 a*d Ae+d Tpe16 C-apter 86
T-e Good-eart4Ai++co@ Co$6 I*c$
HDI i*,ormatio* o* -ttp%MM...$i*du1tr1earc-$com$auMScrap4Meta+4!a+i*/4
Pre114 SM!4 F&:7MpM77985
HEI i*,ormatio* o* -ttp%MM...$ -drau+ic1p*eumatic1$com
H(I i*,ormatio* o* -ttp%MM...$iC1director$comMba+er1M
H&'I i*,ormatio* o* ...$,reepate*t1o*+i*e$com
H&&I i*,ormatio* o* -ttp%MMir1me$*ic$i*M,i+e1MScrapM/t4A=-i+e1-$pd, H&:I
i*,ormatio* o* -ttp%MM...$1a*teci*dia$com
H&5I i*,ormatio* o* ...5$*d$eduMRma*u,actMMPEMS:'pd,T,i+e1MC-&:$pd,
37
Name
Re/$ No a*d Sectio*
Fat-erN 1 Name6 P-o*e *umber
Addre11 ,or commu*icatio*
Co*tact detai+1
Educatio*a+ Lua+i,icatio*1%
SSLC #S o, mar=1 a*d
I*1titutio*)
!$ Tec- #up to 3II Sem)
Future p+a*
I*4p+a*t trai*i*/
P+aceme*t 1tatu1 #Compa*
Name)
Project tit+e #UG)
Project tit+e #PG)M Guide
Add o* pro/ram1 atte*ded
Co*,ere*ce atte*ded
Paper1 Pub+i1-ed .it-
detai+1
Academic a*d 1port1 a.ard1
recei>ed
So,t.are 1=i++1 de>e+oped
Pre>iou1 e@perie*ce i, a*
Date
!O!!" P PAUL
PR&&ME&''(6 II M$TECH #DESIGN)
PROF P PAUL6 Q(&(99D:'EE'& P-oto
URUMPAC2AL HOUSE6 MANNAR2A"AM
P$O6 3IA PON2UNNAM6 2OTTA"AM DIST6
2ERALA6 INDIA6 PIN48E87'8
P-o*e % '9E:E4:':(77
emai+% bobbppau+U/mai+$com
MASTER OF TECHNOLOG"
8($88 HSCM Dip+oma # A1 D8$8
abo>e)
8'$'5 M$ Tec- #up to III Sem) D:
Teac-i*/ Area o, I*tere1t Product De1i/*
3ISHAL PRECISION IAESTE Ni+
PRODUCTS P3T LTD6
COIM!ATHORE
NIL Me*tor *ame Mr Aa+ter 3i*ce*t
COMPILING ECONOMIC ORDER LUANTIT" USING CQQ
DESIGN OF A SCRAP COMPRESSING MACHINE FOR SMALL SCALE
INDUSTRIES
PG Cert6 PRODUCT DESIGN6 INNO3ATION AND MANAGEMENT6
MIDDLESEV UNI3ERSIT"6 LONDON6 :''D
Cert6 ENTERPRISE S2ILL6 0UDGE !USINESS SCHOOL6 CAM!RIDGE6 U$2
NATIONAL SEMINAR ON ;ERGONOMICS FOR ENHANCED
PRODUCTI3IT"< FE! &E
TH
AND &(
TH
ERGONOMIC DESIGN OF A SCRAP COMPACTOR6 ICE :'&56 :
ND
INTERNATIONAL CONFERENCE ON ERGONOMICS6 UNI3ERSIT" OF
MALA"A #PAPER ALREAD" SU!MITTED)
NIL
So+idAor=1 :'&56 A*11 &9$76Pro4E6 Gambit GF+ue*t6 R4STUDIO
INDUSTRIAL ENGINEER6 ORIENT FASHIONS P3T LTD6 :''94:''7
OPERATIONS MANAGER6 "MCA LONDON6 U$2$ :''74:''E
D474:'&5 Si/*ature
38