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Project Report On

Can & Plastic Bottle Crusher

MSE 508 CAD/CAM (Solid Works)

Project Guide

Prof. Richard Walker

Group Members Luis Javier Castellanos

Nikhil Kumar Mistry

Suryakiran Pamudurthy

Tulasiram Arza

Viral Kumar Jayswal

Vijayendrasinh Rathod

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Table of contents:

Sr No Topic Page no

1 Abstract 3

2 Introduction 4

3 Design Synthesis 5

4 Design Evaluation 13

5 Design Analysis 30

6 Manufacturing process 31

7 Rapid Prototyping 32

8 NDT Methods 32

9 Cost Calculation 35

10 Conclusion 36

11 Appendix 37

12 Project management 37

13 Gantt Chart 38

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Abstract:

This Project describes about the design of various components of can or plastic bottle crusher machine which would help to crush the used can or plastic bottles and would thereby help in waste management and disposal. At initial stage we team members searched well for a good project on can or plastic bottle crusher and we got such six different ideas from each team members and diagrams of that given below. Finally we decided a Single slider crank mechanism based can or plastic bottle crusher as project. This project aims to design a portable can or plastic bottle crusher that could be installed anywhere and would aid crush of used can or bottles. This machine is widely used in beverage industries or in scrap dealers shop to reduce the volume of the cans/bottles. Hence in this design of various parts are necessary, and design of various parts due to which the design quality of those parts will be improved. This project is semi-automatic by using electronics equipment like sensors, microcontroller, IC’s etc. along with mechanical components due to which crushed cans or bottles are need not to segregate from bin and also machine will not run idle. After all process has been done, this crusher may help us to understand the fabrication and designing process as well as electronics equipment that involved in this project. After the design has complete, it was transformed to its real product where the design is used for guideline. Crushers are major size reduction equipment used in mechanical and allied industries which crushes different types of soft and hard materials. The can or bottle crusher machine is widely used in beverage industries or in scrap dealers shop to reduce the volume of the cans/bottles. Hence in this design and analysis of various parts are necessary. The Electric Motor and a microcontroller make up the backbone for this project. Overall, this project involves processes like design, fabrication and assembling procedures. This project is mainly about generating a new concept of can or plastic bottle crusher that would make easier to bring anywhere and easier to crush the can or bottle. Keywords: Design consideration, Design process, Single slider crank Mechanism, Can or Plastic bottles, Electric motor, PLC, Sensors, IC’s,

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Introduction:

The sole purpose of this project is to understand the fundamental knowledge of design and mechanism. A can crusher can be defined as “A device used for crushing aluminum cans or plastic bottle for easier storage in recycling bins thereby giving you extra space by flattening of cans”. This project consists of designing and fabrication of a semi-automatic can/bottle crusher machine. In order to reduce the waste, we planned to create a can/bottle crusher that will reduce the volume of aluminum cans/plastic bottles by approximately seventy percent by which transportation volume will increase and transportation cost will reduce. Can crushers are primarily used to save space and for recycling. Also the purpose of this project is to understand the fundamental knowledge of design and single slider crank mechanism a simple mechanism property. A mechanical can/bottle crusher machine is basically one of the most aid able machines. It helps to reduce the pollution of the environment. Thus helps to create a better place to live in, apart from that, this can/bottle crusher can actually be the future mode of recycles apart from the recycle bins. It can be placed everywhere, in the park, houses, restaurants, malls, canteens even in cars. Using a similar type of a design from the diagram below, but with an added bin below the can crusher concept of recycling can be applied. In this project, development of a recycle bin can/bottle crusher so the cans might crush as flat and look as symmetrically as possible and inserted the bin. The designs are an environment friendly and use simple mechanism properties. The design is so done that the knowledge of designing, mechanism and forces. The study of manufacturing was very important in order to carry out this project to ensure that what are needs to do. This project is about designing and fabricating the Recycle Bin Can/Bottle Crusher Machine to help people easy to crush the can as well as bottle and bring anywhere. This project involves the process of designing the different parts of this crusher machine considering forces and ergonomic factor for people to use. After the design has completed, it was transformed to its real product where the design is used for guideline. This project is mainly about generating a new concept of can/bottle crusher that would make easier to bring anywhere and easier to crush the can or bottle. This machine is developed solely for the purpose of recycling as plastic bottles are harmful to environment and aluminum to plants growth. Many people recycles items like paper, glass, and aluminum, While these efforts are a vital part of the process, the true recycling path continues long after recyclables are collected from household bins or community drop-off centers etc. Collecting, processing, manufacturing, and purchasing recycled products create a closed circle or loop that ensures the value of recycling. Recycling is a series of activities that includes the collection of used, reused, or unused items that would otherwise be considered waste, sorting and processing the recyclable products into raw materials, and remanufacturing the recycled raw materials into new products. At initial stage we team members searched well for a good project on can or plastic bottle crusher and we got such six different ideas from each team members and diagrams of that given below. Finally we decided a Single slider crank mechanism based can or plastic bottle crusher as project.

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DESIGN PROCESS Design Synthesis: This is about designing and fabricating the Recycle Bin Can/Bottle Crusher Machine to help people easy to crush the can as well as bottle and bring anywhere. This project involves the process of designing the different parts of this crusher machine considering forces and ergonomic factor for people to use. While developing this design we have considered several attributes like manufacturing ease, cost of manufacturing, maintenance, portability and conventional way of using it. Design Representation: We have six preliminary ideas about the project Design 1: Slider Crank bearing bottle crusher mechanism

Slider crank bearing bottle crusher In this mechanism rotary motion generated from motor which transmits into the reciprocating motion of the slider through different sizes of pulleys. From slider a piston may be connected which will crush the bottle or can. The major components used in this mechanism are

Motor

Pulleys

Shafts

Bearings

Connecting rod

Crank

Slider

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Constraints in this mechanism:

Complicated design

High maintenance

High cost

Not conventional

Design 2: Pulley and V belt drive mechanism

Pulley and V belt drive mechanism

In this mechanism rotary motion generated from the motor through the V belt and pulley is been

converted to reciprocating motion of the slider. We will have two sliders, one slider is fixed and

another slider is operated by pulleys. Bottle or can is placed between two sliders in a holder and

will get crushed by sliders.

The components used in this mechanism are:

Motor

Pulleys

Belts

Sliders

Holder

Constraints in this mechanism are:

High maintenance

Not portable friendly

High cost

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Design 3: Bottle crusher by pressing

Bottle crusher by pressing

This mechanism involves pressing operation. Place the bottle in the V block (bottom) in a holder

slot and apply an external pressure from the press block (top). Bottle gets crushed and to be

removed manually. This is to be operated manually.

Components used in this mechanism are:

Machined and Galvanized Mild Steel blocks

Constraints in this mechanism are:

Manufacturing time

Manually operated

Design 4: Bevel gear bottle crusher

Bevel gear bottle crusher

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In this mechanism motor is connected to bevel gears and generates a reciprocating motion. Bevel

gear is connected to shaft which is connected to spur gears and with a connecting shaft it is

connected to pulleys which will makes the slider in a linear motion (back and forth). Bottle is placed

in between slider and a crushing hood which is placed in between slider and gear mechanism.

The components used in this mechanism are:

Bevel gears

Spur gears

Connecting shafts

Pulleys

Slider

Crushing hood

Constraints in this mechanism are:

Complexity in manufacturing

Highly dependent in gear mechanism

High cost

Design 5: Spur gear bottle crusher

Spur gear bottle crusher

In this mechanism spurs gears are used and are connected to a hand operated wheel. By using

connecting shafts rotary motion from bevel gears generated by a hand wheel gets converted to a

reciprocating motion. Bottle or can is placed in between the slider and bottle holder and will get

crushed by the slider.

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The components used in this mechanism are:

Handle operated wheel

Spur gears

Sliders

Connecting shafts

Pulleys

Constraints in this mechanism are:

Complexity in manufacturing

High maintenance required

Finalized Idea

Design 6: Can or plastic bottle crusher with a single slider mechanism

The aim of this is to give the complete design information about the Can Crusher machine. In this, the explanations and some other parameters related to the project are included. This machine is basically works on the principle of Single Slider Crank Mechanism which is the heart of this machine and it converts rotary motion into a reciprocating machine to crush the Cans/Plastic bottles. In this, link 1 is fixed and link 2 which is a crank is rotating about fixed link 1 and converts this rotary motion into the reciprocating motion of slider (corresponds to the link 4) by means of connecting rod which corresponds to the link 3. This is the inversion of single slider crank which is obtained by fixing link 1.

Single slider crank mechanism

This mechanism consist of mechanical components:

Sr no Name of component Material

1 Base plates MS & HDG

2 Side plates MS & HDG

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3 Flange for both sec MS & HDG

4 Connecting rod both section

MS & HDG

5 Piston for both sec MS & HDG

6 Cylinder MS & HDG

7 Bolt for CR MS & HDG

8 Nuts for CR MS & HDG

9 Piston fixture for linear movement

MS & HDG

10 Motor shaft MS & HDG

11 Plate cover MS & HDG

This mechanism also consists of electrical components and they are:

a. PLC

b. Sensor IR

c. Connecting wires

d. D.C motor

e. Relay

f. Power cables

Final assembly of slider crank mechanism

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Solid works role:

Here the procedure steps of solid works tools are simply described to design major components

of the project as below

a) Plate:

Select plane

Use central rectangle method

Extrude it till required limit

Make holes according to screw

Plate and Plate Cover

b) Pulley:

Select plane

Sketch circle

Extrude base

Draw sketch construction circle on it

Draw circular pattern on it

Extrude cut on all circle

Make it holes according to screw pattern

Draw small circle on same center

Extrude cut through all

Hole dimensioning to connecting rod

Pulley / Flange

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c) Connecting rod:

Sketch a circle, draw a profile

Swift base the profile

Connecting rod

d) Piston:

Select a plane

Draw rectangle by central method

Draw center line

Offset entities

Draw circle on extra edge of rectangle center line

Draw large circle on same center

Make a big circle on other side

Trip extra portion from center line

Extrude base

Extrude whole circle part

Draw plane on a large circle (side plane)

Extrude base till end point of the rod

Draw small circle on same point center

Extrude cut till end

Mirror on both end up & down

Boss extrude on both end of circle

Draw central rectangle on top view

Extrude cut on both side using mirror

Use fillet

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Piston

Design Analysis:

Connecting rod:

Model Information

Model name: Connecting rod - Second section

Current Configuration: Default

Solid Bodies

Document Name and Reference

Treated As Volumetric Properties

Document Path/Date Modified

Boss-Extrude1

Solid Body

Mass:0.326586 kg Volume:4.14976e-

005 m^3 Density:7870

kg/m^3 Weight:3.20055 N

C:\Users\VJR\Desktop\New

folder\Connecting rod - Second section.SLDPRT Dec 09 19:25:32

2015

Study name Static 1

Analysis type Static

Mesh type Solid Mesh

Thermal Effect: On

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Thermal option Include temperature loads

Zero strain temperature 298 Kelvin

Include fluid pressure effects from SOLIDWORKS Flow Simulation

Off

Solver type FFEPlus

Inplane Effect: Off

Soft Spring: Off

Inertial Relief: Off

Incompatible bonding options Automatic

Large displacement Off

Compute free body forces On

Friction Off

Use Adaptive Method: Off

Result folder SOLIDWORKS document (C:\Users\Gaurang\Desktop\New folder)

Units:

Unit system: SI (MKS)

Length/Displacement mm

Temperature Kelvin

Angular velocity Rad/sec

Pressure/Stress N/m^2

Material properties:

Model Reference Properties Components

Name: Galvanized Steel Model type: Linear Elastic

Isotropic Default failure criterion:

Max von Mises Stress

Yield strength: 2.03943e+008 N/m^2

Tensile strength:

3.56901e+008 N/m^2

Elastic modulus: 2e+011 N/m^2 Poisson's ratio: 0.29 Mass density: 7870 kg/m^3

SolidBody 1(Boss-Extrude1)(Connecting rod - Second section)

Curve Data:N/A

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Loads and fixtures:

Fixture name Fixture Image Fixture Details

Fixed-2

Entities: 2 face(s) Type: Fixed Geometry

Resultant Forces

Components X Y Z Resultant

Reaction force(N) -1.99995 -5.2188e-006 1.5173e-006 1.99995

Reaction Moment(N.m)

0 0 0 0

Load name Load Image Load Details

Force-1

Entities: 2 face(s) Reference: Edge< 1 >

Type: Apply force Values: ---, ---, 1 N

Resultant Forces:

Reaction Forces:

Selection set Units Sum X Sum Y Sum Z Resultant

Entire Model N -1.99995 -5.2188e-006

1.5173e-006 1.99995

Reaction Moments:

Selection set Units Sum X Sum Y Sum Z Resultant

Entire Model N.m 0 0 0 0

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Study results:

Name Type Min Max

Stress1 VON: von Mises Stress 0.0369403 N/m^2 Node: 66928

4367.91 N/m^2 Node: 2077

Connecting rod - Second section-Static 1-Stress-Stress1

Name Type Min Max

Displacement1 URES: Resultant Displacement

0 mm Node: 1

2.52049e-007 mm Node: 58956

Connecting rod - Second section-Static 1-Displacement-Displacement1

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Name Type Min Max

Strain1 ESTRN: Equivalent Strain 1.81357e-013 Element: 20791

1.7343e-008 Element: 11516

Connecting rod - Second section-Static 1-Strain-Strain1

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Plate: Model Information:

Model name: Part3-Plate between two section Current Configuration: Default

Solid Bodies

Document Name and Reference

Treated As Volumetric Properties Document

Path/Date Modified

Mirror2

Solid Body

Mass:11.1416 kg Volume:0.00141571

m^3 Density:7870 kg/m^3

Weight:109.188 N

C:\Users\Gaurang\Desktop\New

folder\Part3-Plate between two

section.SLDPRT Dec 09 19:25:32

2015

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Study Properties:

Study name Static 1

Analysis type Static

Mesh type Solid Mesh

Thermal Effect: On

Thermal option Include temperature loads

Zero strain temperature 298 Kelvin

Include fluid pressure effects from SOLIDWORKS Flow Simulation

Off

Solver type FFEPlus

Inplane Effect: Off

Soft Spring: Off

Inertial Relief: Off

Incompatible bonding options Automatic

Large displacement Off

Compute free body forces On

Friction Off

Use Adaptive Method: Off

Result folder SOLIDWORKS document (C:\Users\Gaurang\Desktop\New folder)

Units:

Unit system: SI (MKS)

Length/Displacement mm

Temperature Kelvin

Angular velocity Rad/sec

Pressure/Stress N/m^2

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Material Properties:

Model Reference Properties Components

Name: Galvanized Steel Model type: Linear Elastic

Isotropic Default failure

criterion: Max von Mises Stress

Yield strength: 2.03943e+008 N/m^2

Tensile strength: 3.56901e+008 N/m^2

Elastic modulus: 2e+011 N/m^2 Poisson's ratio: 0.29

Mass density: 7870 kg/m^3

SolidBody 1(Mirror2)(Part3-Plate between two section)

Curve Data:N/A

Loads and Fixtures

Fixture name Fixture Image Fixture Details

Fixed-1

Entities: 1 face(s) Type: Fixed Geometry

Resultant Forces

Components X Y Z Resultant

Reaction force(N) -3.04235e-005 -6.14689e-005 666.788 666.788

Reaction Moment(N.m)

0 0 0 0

Load name Load Image Load Details

Force-1

Entities: 1 face(s) Type: Apply normal force

Value: 150 lbf

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Mesh Information:

Mesh type Solid Mesh

Mesher Used: Standard mesh

Automatic Transition: Off

Include Mesh Auto Loops: Off

Jacobian points 4 Points

Element Size 0.221083 in

Tolerance 0.0110542 in

Mesh Quality High

Mesh Information details:

Total Nodes 118826

Total Elements 73943

Maximum Aspect Ratio 7.4934

% of elements with Aspect Ratio < 3 97.2

% of elements with Aspect Ratio > 10 0

% of distorted elements(Jacobian) 0

Time to complete mesh(hh;mm;ss): 00:00:12

Computer name: OHM

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Resultant Forces

Reaction forces

Selection set Units Sum X Sum Y Sum Z Resultant

Entire Model

N -3.04235e-005

-6.14689e-005

666.788 666.788

Reaction Moments

Selection set Units Sum X Sum Y Sum Z Resultant

Entire Model

N.m 0 0 0 0

Study Results:

Name Type Min Max

Stress1 VON: von Mises Stress 305.796 N/m^2 Node: 109357

17084.8 N/m^2 Node: 116059

Part3-Plate between two section-Static 1-Stress-Stress1

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Name Type Min Max

Displacement1 URES: Resultant Displacement

0 mm Node: 441

6.02297e-007 mm Node: 2870

Part3-Plate between two section-Static 1-Displacement-Displacement1

Name Type Min Max

Strain1 ESTRN: Equivalent Strain

1.67681e-009 Element: 29204

5.74077e-008 Element: 17527

Part3-Plate between two section-Static 1-Strain-Strain1

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Flange:

Model Information

Model name: Part1-Flange - second section Current Configuration: Default

Solid Bodies

Document Name and Reference

Treated As

Volumetric Properties

Document Path/Date Modified

Boss-Extrude2

Solid Body

Mass:0.503049 kg Volume:6.39198e-005 m^3 Density:7870 kg/m^3 Weight:4.92988 N

C:\Users\Gaurang\Desktop\New folder\Part1-Flange - second section.SLDPRT Dec 09 19:25:32 2015

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Study Properties:

Study name Static 1

Analysis type Static

Mesh type Solid Mesh

Thermal Effect: On

Thermal option Include temperature loads

Zero strain temperature 298 Kelvin

Include fluid pressure effects from SOLIDWORKS Flow Simulation

Off

Solver type FFEPlus

Inplane Effect: Off

Soft Spring: Off

Inertial Relief: Off

Incompatible bonding options Automatic

Large displacement Off

Compute free body forces On

Friction Off

Use Adaptive Method: Off

Result folder SOLIDWORKS document (C:\Users\Gaurang\Desktop\New folder)

Units:

Unit system: SI (MKS)

Length/Displacement Mm

Temperature Kelvin

Angular velocity Rad/sec

Pressure/Stress N/m^2

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Material Properties:

Model Reference Properties Components

Name: Galvanized Steel Model type: Linear Elastic

Isotropic Default failure

criterion: Max von Mises Stress

Yield strength: 2.03943e+008 N/m^2

Tensile strength: 3.56901e+008 N/m^2

Elastic modulus: 2e+011 N/m^2 Poisson's ratio: 0.29

Mass density: 7870 kg/m^3

SolidBody 1(Boss-Extrude2)(Part1-Flange - second section)

Curve Data:N/A

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Loads and Fixtures:

Fixture name Fixture Image Fixture Details

Fixed-1

Entities: 1 face(s) Type: Fixed Geometry

Resultant Forces

Components X Y Z Resultant

Reaction force(N) 2.40966e-008 1.26893e-008 1.55032e-008 3.13371e-008

Reaction Moment(N.m)

0 0 0 0

Load name Load Image Load Details

Force-1

Entities: 1 face(s) Type: Apply normal force

Value: 1 N

Mesh Information:

Mesh type Solid Mesh

Mesher Used: Standard mesh

Automatic Transition: Off

Include Mesh Auto Loops: Off

Jacobian points 4 Points

Element Size 0.0787326 in

Tolerance 0.00393663 in

Mesh Quality High

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Mesh information – Details

Total Nodes 84810

Total Elements 56686

Maximum Aspect Ratio 3.8734

% of elements with Aspect Ratio < 3 99.9

% of elements with Aspect Ratio > 10 0

% of distorted elements(Jacobian) 0

Time to complete mesh(hh;mm;ss): 00:00:02

Computer name: OHM

Resultant Forces

Reaction forces

Selection set Units Sum X Sum Y Sum Z Resultant

Entire Model N 2.40966e-008

1.26893e-008

1.55032e-008

3.13371e-008

Reaction Moments

Selection set Units Sum X Sum Y Sum Z Resultant

Entire Model N.m 0 0 0 0

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Study results:

Name Type Min Max

Stress1 VON: von Mises Stress 0.453725 N/m^2 Node: 79200

4608.69 N/m^2 Node: 83498

Part1-Flange - second section-Static 1-Stress-Stress1

Name Type Min Max

Displacement1 URES: Resultant Displacement

0 mm Node: 757

1.93097e-007 mm Node: 83575

Part1-Flange - second section-Static 1-Displacement-Displacement1

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Name Type Min Max

Strain1 ESTRN: Equivalent Strain 9.51876e-012 Element: 11688

1.79416e-008 Element: 16056

Part1-Flange - second section-Static 1-Strain-Strain1

Simulation Conclusion:

For crushing the bottle you might not need that much of pressure from the external force, it may be 50 IPS could be enough but we had applied thrice of that force so we could get Idea about deflection, and as shown in figure after got report of simulation the component got bended out of reach of acceptance force.so we can strongly conclude about stress analysis that if product does not bear the external force of desired value then should stop processing and try to find out missing input which can accept that value.

Design Evaluation:

We have made decision matrix of design evaluation and below is the matrix.

Decision Matrix

Designs/Ideas Manufacturing Coventional Cost Portability Maintenance Score

Slider crank bearing Mechanism 5 5 5 7 5 5

Pulley and V belt mechanism 6 6 6 7 6 6

Pressing mechanism 6 6 8 8 8 7

Bevel gear Mechanism 2 5 9 6 4 5

Spur gear Mechanism 2 5 9 5 4 5

Slider Crank Mechanism 9 8 9 9 9 9

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First row consists of the designs and all the other rows are attributes we have added to finalize

our design. Attributes we have used are manufacturing ease, conventional use, cost to

manufacture the mechanism, portability of the mechanism and finally maintenance. By the

decision matrix we moved forward with Slider crank mechanism and starting designing all the

parts.

PDR and CDR:

We have 6 preliminary designs before proceeding with the finalized design, we had a several brain

storming sessions before generating a decision matrix. We have looked into every aspect right

from the raw material to final cost of producing an equipment. The finalized design is easy to

operate and have less maintenance. By the decision matrix we have reviewed every design and

finally we went ahead with slider crank mechanism.

MANUFACTURING PROCESS:

The design and manufacturing are an environment friendly and uses simple mechanism properties such as fulcrum system, single slider crank mechanism and automation properties etc. In this, some crushing force is needed to crush the cans/bottles to reduce its volume by large extent. The design is so done that the knowledge of designing, mechanism and forces are increased. This project consists of designing and fabrication of an automatic can crusher machine considering various important parameters. In this project, development of a recycle bin can/bottle crusher so the Can/bottle might crush as flat and look as symmetrically as possible and inserted the bin. As well as the study of manufacturing was very important in order to carry out this project to ensure that what are needs to do. This project involves the process of designing the different parts of this crusher machine considering forces and ergonomic factor for people to use. This project is mainly about generating a new concept of can/bottle crusher that would make easier to bring anywhere and easier to crush the can or bottle. After the design has completed, it was transformed to its real product where the design is used for guideline.

The 1st stage the design of base plate was done. The basic idea behind this project is to manufacture such a machine crusher that could be placed on recycle cans and crushing operation could be carried out easily. Also the crusher should be portable for transport replacement and maintenance. In the 2nd stage the crushing mechanism was designed. Experimentally it was found that

the bottom and top portions of bottle are hard and thus it is difficult to crush the bottle along its

axis. Crushing a bottle latterly would require greater force and produce more vibration. Also

crushing the bottle latterly would not produce a optimally compressed waste i.e. the force

required is more and the area the crushed product occupies is also greater than the axially

compressed waste. Considering all these factors a reciprocating mechanism was incorporated to

crush bottle along its axis. The Crushing operation that is the desired action is carried out in only

one stroke of cycle. A flywheel is connected between the reciprocating ram and driving mechanism

to store the energy in idle stroke and deliver it in the operational stroke of crushing. Thus the

flywheel is incorporated in design. In this way the mechanism is made more efficient. Also the

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flywheel acts as an intermediate link to connect the driving mechanism and the ram. The end of

the link connected to ram is attached to flywheel and thus motion is transmitted.

In the further stage of design driving mechanism for the flywheel and reciprocating parts

where designed. The design of driving mechanism should be such that maximum torque should

be transmitted. However the speed can be compensated to increase the torque.

Rapid Prototyping:

Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a physical

part or assembly using three-dimensional computer aided design (CAD) data. Construction of the

part or assembly is usually done using 3D printing or "additive layer manufacturing" technology.

Non Destructive Testing (NDT):

Nondestructive testing (NDT) is the process of inspecting, testing, or evaluating materials,

components or assemblies for discontinuities, or differences in characteristics without destroying

the serviceability of the part or system. In other words, when the inspection or test is completed

the part can still be used.

In contrast to NDT, other tests are destructive in nature and are therefore done on a limited number of samples ("lot sampling"), rather than on the materials, components or assemblies actually being put into service.

These destructive tests are often used to determine the physical properties of materials such as impact resistance, ductility, yield and ultimate tensile strength, fracture toughness and fatigue strength, but discontinuities and differences in material characteristics are more effectively found by NDT.

Today modern nondestructive tests are used in manufacturing, fabrication and in-service inspections to ensure product integrity and reliability, to control manufacturing processes, lower production costs and to maintain a uniform quality level. During construction, NDT is used to ensure the quality of materials and joining processes during the fabrication and erection phases, and in-service NDT inspections are used to ensure that the products in use continue to have the integrity necessary to ensure their usefulness and the safety of the public.

Non Destructive Test Methods:

Test method names often refer to the type of penetrating medium or the equipment used to perform that test. Current NDT methods are:

1) Acoustic Emission Testing (AE) 2) Electromagnetic Testing (ET)

3) Guided Wave Testing (GW) 4) Ground Penetrating Radar (GPR)

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5) Laser Testing Methods (LM) 6) Leak Testing (LT)

7) Magnetic Flux Leakage (MFL) 8) Magnetic Particle Testing (MT)

9) Neutron Radiographic Testing (NR) 10) Radiographic Testing (RT)

11) Thermal/Infrared Testing (IR) 12) Ultrasonic Testing (UT)

13) Vibration Analysis (VA) 14) Visual Testing (VT).

15) Microwave Testing, Liquid Penetrant Testing (PT)

As our project detail components list, we can apply many NDT test methods to identify atomic structure or internal component cavities. Here we can apply very popular NDT test method ‘Radiographic Testing (RT)’ to each project detail component as below.

NDT- Radiographic Testing (RT):

Fig.

Industrial radiography involves exposing a test object to penetrating radiation so that the radiation

passes through the object being inspected and a recording medium placed against the opposite

side of that object. For thinner or less dense materials such as aluminum, electrically generated

x-radiation (X-rays) are commonly used, and for thicker or denser materials, gamma radiation is

generally used.

Gamma radiation is given off by decaying radioactive materials, with the two most commonly used

sources of gamma radiation being Iridium-192 (Ir-192) and Cobalt-60 (Co-60). IR-192 is generally

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used for steel up to 2-1/2 - 3 inches, depending on the Curie strength of the source, and Co-60 is

usually used for thicker materials due to its greater penetrating ability.

The recording media can be industrial x-ray film or one of several types of digital radiation

detectors. With both, the radiation passing through the test object exposes the media, causing an

end effect of having darker areas where more radiation has passed through the part and lighter

areas where less radiation has penetrated. If there is a void or defect in the part, more radiation

passes through, causing a darker image on the film or detector, as shown in Figure.

Radiographic Testing (RT) Techniques:

Film Radiography:

Film radiography uses a film made up of a thin transparent plastic coated with a fine layer of silver

bromide on one or both sides of the plastic. When exposed to radiation these crystals undergo a

reaction that allows them, when developed, to convert to black metallic silver. That silver is then

"fixed" to the plastic during the developing process, and when dried, becomes a finished

radiographic film.

To be a usable film, the area of interest (weld area, etc.) on the film must be within a certain

density (darkness) range and must show enough contrast and sensitivity so that discontinuities of

interest can be seen. These items are a function of the strength of the radiation, the distance of

the source from the film and the thickness of the part being inspected. If any of these parameters

are not met, another exposure ("shot") must be made for that area of the part.

Computed Radiography:

Computed radiography (CR) is a transitional technology between film and direct digital radiography. This technique uses a reusable, flexible, photo-stimulated phosphor (PSP) plate which is loaded into a cassette and is exposed in a manner similar to traditional film radiography. The cassette is then placed in a laser reader where it is scanned and translated into a digital image, which take from one to five minutes. The image can then be uploaded to a computer or other electronic media for interpretation and storage.

Computed Tomography:

Computed tomography (CT) uses a computer to reconstruct an image of a cross sectional plane of an object as opposed to a conventional radiograph, as shown in Figure 9. The CT image is developed from multiple views taken at different viewing angles that are reconstructed using a computer. With traditional radiography, the position of internal discontinuities cannot be accurately determined without making exposures from several angles to locate the item by triangulation. With computed tomography, the computer triangulates using every point in the plane as viewed from many different directions.

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Digital Radiography:

Digital radiography (DR) digitizes the radiation that passes through an object directly into an image that can be displayed on a computer monitor. The three principle technologies used in direct digital imaging are amorphous silicon, charge coupled devices (CCDs), and complementary metal oxide semiconductors (CMOSs). These images are available for viewing and analysis in seconds compared to the time needed to scan in computed radiography images. The increased processing speed is a result of the unique construction of the pixels; an arrangement that also allows a superior resolution than is found in computed radiography and most film applications. Cost Calculation: Considering steel, fabrication and galvanizing process as per Indian rupees (INR)

Part Weight in

Kg Fabrication

price Galvanizing

Price

Flange 1 14 18

Plate 45.4 635.6 817.2

Rod 0.652 9.128 11.736

Piston 1 14 18

Hardware 0.25 3.5 4.5

Total Cost

48.302 676.228 869.436

Final Cost 4443.784

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CONCLUSION:

From the above study, it is observed that by arranging different mechanical components along with electronic components machine can be made automatic one to crush the Cans as well as plastic bottles solely to reduce the volume. Thus human efforts can be reduced as well as time also, because sorting system is installed there to separate the bottles and cans to reduce the human fatigue. As above results shows that the volume can be reduced to a large extent i.e. near about seventy percent volume can easily be reduced, thus transportation volume can be increased and transportation cost can be reduced to a large extent and these can be reuse.

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APPENDIX: Project Management: Group Structure:

CSUN Manufacturing Inc.

Design Team Analysis Team Documentation

Team

Final Product

Decision Making

Product Review

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Gantt Chart:

0 5 10 15

Group disscussion

Idea collection

Finalized Idea

Components drawings

Assembly

Disscussion

Working piece

Reports

Gantt Chart