Design of Impact Stone Crushing Machine

ADAMA SCIENCE AND TECHNOLOGY UNIVERSITY
School of Mechanical Chemical and Material Engineering
Department of Mechanical and vehicle engineering
Design of impact stone crusher machine
June, 2015
a
ADAMA SCIENCE AND TECHNOLOGY UNIVERSITY

Department of Mechanical and Vehicle Engineering
Design of impact stone crusher machine
Project submitted in partial fulfillment of the

Requirements for the award of the degree of
BACHELOR OF SCIENCE
IN
MECHANICAL ENGINEERING
By
Tesfaye Olana
03035670
Gemechu Gutema
03035126
Tsega Tadesse
02023398
Advisor: Getaw Ayay (M.Sc.)
Adama
2015
b
Design of impact stone crusher machine, 2015
ADAMA SCINCE AND TECHINOLOGY UNIVERSITY

Department of Mechanical and Vehicle Engineering
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Abstract
Crushers are one of the major size reduction equipment that is used in metallurgical, mechanical,
and other similar industries. They exist in various sizes and capacities which range from 30 ton/hr.
to 1000 ton/hr. They can be classified based on the degree to which they can fragment the
starting material and the way they apply
forces. Based on the mechanism used crushers are
basically of three types ; namely, Cone crusher, Jaw crusher and Impact crusher. Our objective is to
design impact stone crusher. In this case we need to design various components of impact stone crusher
like drive mechanisms, shaft, rotor plate, hammers, Key way, flywheel, Pulley, casing, screening
and V-belts which was useful in minimizing weight, cost and maximizing the capacity and also
do the component simulation analysis. Impact stone crusher involves the use of impact rather
than pressure to crush materials. Here the material is held within a cage, with openings of the
desired size at the bottom, end or at sides to allow crushed material to escape through them. This
type of crusher is generally used with soft materials, medium to hard stones and medium hard
metallic ores. The mechanism applied here is of impact loading where the time of application of
force is less than the natural frequency of vibration of the body. Since the hammers are rotating
at a very high speed, the time for which the particles come in contact with the hammers is very
small, hence here impact loading is applied. The shaft is considered to be subjected to torsion and
bending. There are different sizes of aggregates in Ethiopia commonly known as 01, 02, 03 and 04 are
stockpiled separately. Size 02 means aggregates having a maximum aggregate size of 20mm,while 01, 03,
04 has a maximum aggregate size of 10, 30 and 40 mm respectively. For these different sizes of
aggregates the grinding screen is also designed for optimal output from the crusher. Generally,
impact stone crusher machine is widely used in mining, highway and railway, construction material
and other related industries.
Acknowledgement
First of all our gratitude goes to the almighty God and during this project work, there were many
people who were helping us. Without their guidance, help and patience, we would have never been
able to accomplish the work of this project. We would like to take this opportunity to acknowledge
some of them.
We would like to express our gratitude to our project Advisor, Ato. Getaw Ayay (M.Sc.), for exposing us
to such kind of explorative and investigative project work. His encouragement, excellent guidance,
creative suggestions and critical comments have greatly contributed to this project work. By letting
us to work on such interesting topic, he enabled us to broaden our thought through reading lots of
available materials. We would also like to thank Ato. Elias Habtu (M.Sc.) from (ASTU Mechanical and
Vehicle Engineering Department) for his special suggestion of some starting ideas he gave to us.
ii
LIST OF CONTENTS
Abstract .......................................................................................................................................................................... i
Acknowledgement ......................................................................................................................................................... ii
LIST OF CONTENTS ........................................................................................................................................................ iii
LIST OF TABLES .............................................................................................................................................................. v
LIST OF FIGURES ............................................................................................................................................................ v
NOMENCLUTURE .......................................................................................................................................................... vi
1. INTRODUCTION ......................................................................................................................................................... 1
1.1. Background ......................................................................................................................................................... 1
1.2. Statement of the Problem .................................................................................................................................. 2
1.3. Objective of the project ...................................................................................................................................... 2
1.4. Scope of the project ........................................................................................................................................... 3
1.5. Design methodology ........................................................................................................................................... 3
2. LITRETURE REVIEW .................................................................................................................................................... 5
2.1. Crushing Technology .......................................................................................................................................... 5
2.2. Classification of crusher...................................................................................................................................... 7
2.3. Types of impact stone crusher ........................................................................................................................... 8
2.4. Advantages of the horizontal over Vertical shaft impact stone crusher ............................................................ 8
2.5. Locally available types of stone .......................................................................................................................... 9
3. PRELIMINARY DESIGN..............................................................................................................................................11
3.1. Concept development ......................................................................................................................................11
3.2. Concept evaluation and decision .....................................................................................................................12
3.3. Operational principle of the machine ..............................................................................................................13
4. MATHEMATICAL SIMULATION ................................................................................................................................14
4.1. Application of law of conservation of moments to impact ..............................................................................14
4.2. Static stresses and displacement......................................................................................................................15
4.3. Kinetics and kinematics of hammer rotation ...................................................................................................15
4.4. Parametric mathematical simulation ...............................................................................................................17
5. MATERIAL SELECTION AND DETAIL DESIGN ............................................................................................................19
5.1. Design of hammer ............................................................................................................................................19
5.2. Design of rotor plate.........................................................................................................................................25
5.4. Design of the pulley ..........................................................................................................................................34
5.5. Design of belt drive...........................................................................................................................................36
iii

5.6. Design for driven pulley ....................................................................................................................................42
5.7. Design of shaft ..................................................................................................................................................44
5.8. Selection of bearing ..........................................................................................................................................49
5.9. Motor selection ................................................................................................................................................52
5.10. Design of Anvils ..............................................................................................................................................54
5.11. Design of size reducer shaft ...........................................................................................................................57
5.12. Design of spring ..............................................................................................................................................58
5.13. Design of grinding screen ...............................................................................................................................60
5.14. Design of Housing (Casing) .............................................................................................................................64
5.16 Design of mass unbalance ...............................................................................................................................69
6. DESIGN FOR MANUFACTURING PROCESS ...............................................................................................................72
6.1. Manufacturing process by casting ....................................................................................................................72
6.2. Manufacturing by machining............................................................................................................................74
6.3. The Manufacturing Process of spring ...............................................................................................................79
6.4. Pin manufacturing by forging ...........................................................................................................................79
7. MANUAL OF THE MACHINE .....................................................................................................................................80
7.1 Maintenance......................................................................................................................................................80
7.2 Assembly process ..............................................................................................................................................82
7.3 Disassembly process ..........................................................................................................................................82
8. COST ESTIMATION ...................................................................................................................................................83
8.1. Cost estimation methodology ..........................................................................................................................83
8.2 Material cost ......................................................................................................................................................83
8.3 Labour cost ........................................................................................................................................................84
9. CONCLUSION AND RECCOMMENDATION ...............................................................................................................85
9.1 Conclusion .........................................................................................................................................................85
9.2 Recommendation ..............................................................................................................................................85
APPENDIX.....................................................................................................................................................................86
REFERANCE ................................................................................................................................................................132
iv
LIST OF TABLES
Table 3.1 concept evaluation and decision ................................................................................. 13
Table 6.1: weight of parts manufacture by casting ...................................................................... 72
LIST OF FIGURES
Figure 1.1: A man crushing stone traditionally ............................................................................. 2
Figure 2.1: rotor assembly and housing/ casing of concept one ...................................................... 11
Figure 2.2: rotor assembly and casing of concept two .................................................................. 11
Figure 2.3: rotor assembly and overall assembly of concept three .................................................. 16
Figure 4.1: A single particle just after the rotor bar of a hammer crusher ........................................ 21
Figure 5.1: cantilever beam subjected concentrated load at the tip ................................................. 22
Figure 5.2: cantilever beam subjected concentrated load at the middle ........................................... 23
Figure 5.3: cantilever beam subjected to distributed load ............................................................. 23
Figure 5.4: strain energy diagram ........................................................................................... 23
Figure 5.5: Bending part of rotor plate ...................................................................................... 25
Figure 5.6: Geometry of flywheel rims ...................................................................................... 30
Figure 5.7: Flywheel cantilever beam ....................................................................................... 32
Figure 5.8: Cross section of v grooved pulley ............................................................................. 35
Figure 5.9: Geometry of angle contact for both pulleys. ............................................................... 41
Figure 5.10: total weight on the shaft ........................................................................................ 46
Figure 5.11: shear and bending moment diagram ........................................................................ 47
Figure 512: Free body rotating unbalance ................................................................................. 70
NOMENCLUTURE
ASME = American Society of Mechanical Engineers
AISI = American iron and steel institute
CAD = Computer aided drafting
IPR = inches per revolution
IPM = inches per minute
SF = service factor
SFM = surface feet per minute
TPH= Tone per hour
rpm = revolution per minute
hb = Height of fall of material
m2 = mass of hammer
m1 = mass of stone
u1 = speed of stone
u2 = speed of hammer
= Density
E= Youngs Modulus
ys= Yield Stress
W= Total weight
V = speed of particle and hammer after impact together
N = speed rpm
Z = number of hammer
ni = number of impact
Vp = propagation velocity
d = dynamic stress
P = Equivalent static force

ym = deflection
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Fc = crushing force
I = moment of inertia
all = allowable stress
Mmax = Maximum moment
Spy = Yield strength
Mall = maximum allowed bending moment
b = Bending stress
= shear stress
G = modules of rigidity
fs = factor of safety
P = power used to drive the shaft
di = Inner diameter of flywheel (diameter of the shaft)
Cf = Coefficient of fluctuation
V = Poisons ratio
max = maximum angular speed
min = minimum angular speed
ave = average or nominal shaft speed
= Angular speed
N1 = Minimum speed in rpm
N2 = Minimum speed in rpm during the cycle
KE = Kinetic energy
k = radius of gyration
= Mechanical efficiency
CE = coefficient of fluctuation of energy
W = work done per cycle
Tmean = mean torque on the shaft
m = mass
A = Cross-sectional area of rim
b = Width of the rim
D = Mean diameter of flywheel
R = Mean radius of flywheel
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v = Linear velocity of flywheel
t = Tensile or hoop stress
Z = Section modulus
= Total tensile stress
T = Maximum torque transmitted by the shaft
r = Radius of the hub
n = Number of arms
= material weight density
A = capacity factor
B = retained material factor
C = Half size factor
= coefficient of friction
v = Speed of the belt in meters per minute
X = Center distance of the belt
WR = Radial load
WA = Axial load
YO = Radial load factor
XO = Axial load factor
L = Rating life
C = Basic dynamic load bearing
Pi = Initial tension in a bolt
d = Nominal diameter of bolt, in mm
P = Maximum safe axial load
dc = Core or minor diameter
dp =Pitch diameter
Average thread shearing stress for the nut
Compretion or Crashing stress
n = Number of threads in engagement
l = Length of the shank of the bolt
Maximum principal shear stress
(
Maximum principal tensile stress

viii
1. INTRODUCTION
1.1. Background
In industry, crushers are machines which use a metal surface to break or compress materials into small
fractional denser masses. Throughout most of industrial history, the greater part of crushing and mining
part of the process occurred under muscle power as the application of force concentrated in the tip of the
miners pick or sledge hammer driven drill bit. Before explosives came into widespread use in bulk mining
in the mid-nineteenth century, most initial ore crushing and sizing was by hand and hammers at the mine
or by water powered trip hammers in the small charcoal fired smithies and iron works typical of the
renaissance through the early-to-middle industrial revolution. It was only after explosives, and later early
powerful steam shovels produced large chunks of materials, chunks originally reduced by hammering in
the mine before being loaded into sacks for a trip to the surface, chunks that were eventually also to lead
to rails and mine railways transporting bulk aggregations that post-mine face crushing became widely
necessary. The earliest of these were in the foundries, but as coal took hold the larger operations became
the coal breakers that fueled industrial growth from the first decade of the 1600s to the replacement of
breakers in the 1970s through the fuel needs of the present day. The gradual coming of that era and
displacement of the cottage industry based economies was itself accelerated first by the utility of wrought
and cast iron as a desired materials giving impetus to larger operations, then in the late-sixteenth century
by the increasing scarcity of wood lands for charcoal production to make the newfangled window glass
material that had become along with the chimney 'all the rage' among the growing middle-class and
affluence of the sixteenth and seventeenth centuries; and as always, the charcoal needed to smelt metals,
especially to produce ever larger amounts of brass and bronze, pig iron, cast iron and wrought iron
demanded by the new consumer classes. Other metallurgical developments such as silver and gold mining
mirrored the practices and developments of the bulk material handling methods and technologies feeding
the burgeoning appetite for more and more iron and glass, both of which were rare in personal possessions
until the 1700s.
With gunpowder being increasingly applied to mining, rock chunks from a mining face became much
larger, and the blast dependent mining itself had become dependent upon an organized group, not just an
individual swinging a pick. Economies of skill gradually infused industrial enterprises, while transport
became a key bottleneck as the volume of moved materials continued to increase following demand. This
spurred numerous canal projects, inspired laying first wooden, then iron protected rails using draft animals
to pull loads in the emerging bulk goods transportation dependent economy. In the coal industry, which
grew up hand in hand as the preferred fuel for smelting ores, crushing and preparation (cleaning) was
1

performed for over a hundred years in coal breakers, massive noisy buildings full of conveyors, beltpowered trip hammer crushing stages and giant metal grading/sorting grates. Impact Crusher features
many advantages: new technique, unique structure, cubic shaped desired products. Impact Crusher can
deal with materials with the feeding size less than 500mm and compressive resistance not more than
500Mpa despite of the large, middle or small size hard. This machine is widely using in mining, highway
and railway, construction material and other related industries. The final size can adjust and there are
many models for the crushers.
1.2. Statement of the Problem
At present, Ethiopias economic construction and rapid development enhances the need of the gravel and
aggregate for the construction site. The normal weight coarse aggregates for the Ethiopian construction
sector are produced by both, traditional and modern means. Traditionally coarse aggregate is produced by
heating a stone at a higher temperature and crushing it by a hammer using a manual labor to the required
approximate sizes. Aggregates produced using such method are usually flaky (peeling) and do not satisfy
the grading requirements set by standard recommendations. Nevertheless, such aggregates are used for
construction in areas where aggregates crushing machine(s) is not available and quality control is not a
criteria in the execution of the work. In preparing crushing it manually by hammer which consumes long
time, take maximum money, need many human powers and has many injure on human body. So design of
this machine was necessary.
Figure 1.1: A man crushing stone traditionally

1.3. Objective of the project
1.3.1. General objective
Construction is clearly a critical enabling condition for improving living conditions in both rural and
urban areas. This is achieved if and only if the stone crusher which will fill the demand of aggregates is
designed. So design of this machine will intend to fill this demand. So our main objective of the project is
to design the impact stone crusher.
2

1.3.2. Specific objective
various components of an Impact stone crusher like drive mechanism, shaft, rotor plate, hammers,
casing, screening and V-belts which will be useful in minimizing weight, low time consuming, cost
and maximizing the capacity will be designed.
It will reduce injuries that may face on human body while they are hammering aggregate using
hammer manually, required labor force, minimize time to prepare aggregate and cost paid for manual
workers.
Finally, assembly and show its simulation using CATIA V5 or SOLIDWORK.
1.4. Scope of the project
From the title that has been chosen, the development of this project must include how to design the
mechanical part of machine using advanced software( like AutoCAD, Catia or solid works) and analysis
numerically of this mechanical part. The machine would have 50kg/s (180TPH) of producing aggregate
products. It also needs some knowledge and skill to finish the project. There is some other guide that must
be followed to finish this project.
1.5. Design methodology
1.5.1. Preliminary design
Defining the problem and gathering information regarding to the crushing machine
Surveying different literature (journals and books) about the stone crusher machine
Developing different concept on how to design the machine regarding with the appearance, capacity,
overall dimension, etc.
Selecting the concept and reviewing the design
1.5.2. Embodiment design
a) Configuration design of parts and components
Determine what features will be present and how those features are to be arranged in space relative to
each other.
The general material properties for the machine will be elaborated and material will be selected for
each part of the machine
b) Parametric design of parts
Configuration of the part and aims to establish its exact dimensions and tolerances will be held on.
Final decisions on the material and manufacturing processes are also established

1.5.3. Detail design
In this phase the design is brought to the stage of a complete engineering description of producible
product. Missing information is added on the arrangement, form, dimensions, and tolerances, surface
properties, materials, and manufacturing processes of each part. In the detail design phase the following
activities are completed and documents are prepared: Detailed engineering drawings suitable for manufacturing. Routinely these are Computer-generated
drawings and they often include two dimensional, three dimensional drawing of Catia or solid work
models.
Assembly drawings and assembly instructions also will be completed. The bill of materials for all
assemblies will be completed.
With the preceding information, a detailed cost estimate for the product will be carried out.
Finally, detail design concludes with a design review before the decision is made to pass the design
information on to manufacturing.
2. LITRETURE REVIEW
2.1. Crushing Technology
A crusher is a machine that is designed to reduce large solid masses of raw material into smaller portions.
Crushing is the process of transferring a force amplified by mechanical advantage through a material
made of molecules that bond together more strongly, and resist deformation more than those in the
material being crushed do. Crushing devices hold material between two parallel or tangent solid surfaces
and apply sufficient force to bring the surfaces together to generate enough energy within the material
being crushed.
Crushers are commonly classified by the degree to which they fragment the starting material with primary
crushers that do not have much fineness, intermediate crushers having more significant fineness and
grinders reducing it to a fine power.
Various types of crushers are used in the stone crushing industry such as Jaw Crushers, Roller Crushers,
Cone Crushers, Impactor, Rotopoctor etc. Generally, only Jaw crushers are used as Primary crushers. For
secondary and tertiary crushing application either of Jaw, cone, roller, Impactor or Rotopoctor type
crushers are used. Various types of crushers are briefly described below.
A) Jaw crushers
These are the oldest type of and the most commonly used crushers in use and have changed little from the
original design. In Jaw Crusher the feed is compressed between a stationary and a movable surface. A few
of common types of Jaw crushers, in use, are described below
Double toggle jaw crusher: - The Blake jaw crusher has a fixed jaw and a moving jaw pivoted at the
top. The crushing faces themselves are formed either of manganese steel or of chilled cast iron. The
maximum pressure is exerted on the large material, which is introduced at the top. These crushers are
made with jaw widths varying from about 2 to 48 and the running speed varies from about 100 to
400 RPM.
Single toggle jaw crusher: - The single-toggle crusher is the simplest and the lightest of the jaw
crushers but is suitable only for producing low crushing forces and therefore used for soft rocks.
Impact jaw crusher: - In this type of crusher the crusher cavity is inclined. As there is larger stroke
and higher rotation speed (about 400 rpm) a stronger impact is achieved. As a result, hard, tough
materials can be processed.
B) Gyratory( cone ) crusher
In Gyratory Crushers the stress to the feed is applied between a stationary and a movable surface. The
crushing head is employed in the form of a truncated cone, mounted on a shaft, the upper end of which is
5

held in a flexible bearing, whilst the lower end is driven eccentrically so as to describe a circle. The
crushing action takes place around the cone.
Primary Gyratory Crusher: In the primary gyratory crusher the stress is applied to the feed by
pressure as the conical head periodically approaches the bowl. The primary Gyratory Crusher is a
large, heavy and expensive machine. It is used only for special materials and high through put. As the
crusher is continuously in action, the fluctuation in the stresses is smaller compared to the jaw crusher
but the power consumption is lower. It gives a finer and more uniform product compared to the jaw
crusher.
Cone Crusher: Cone crusher have shallower cavity than that of the primary gyratory crusher. This
crusher produces higher reduction ratios of up to 18. A uniform product size and good shape is
ensured because of the long parallel gap before aperture. The stroke is large and the speed of rotation
is 200 - 300 rpm, which ensures a cubical shape to the product. The shallow cone crushers are mainly
used for the fine crushing of hard and moderately hard materials.
C) Roller crusher
The roller crushers operate on the principal that the stress (to the feed) is applied between the rollers or
between a roller and a crushing surface.
Double Roll Crusher: Double roll crusher consists of two rollers, which rotate towards each other and
are separated by an adjustable gap. The gap can be adjusted according to the size of the feed and the
required size of the product. Rollers with diameters up to 2m can handle feed sizes up to 1m.With soft
to moderately hard materials, throughputs as high as 3500TPH. can be achieved.
Single-Roll Crusher: In the single roll crusher, a crushing roller acts against a crushing plate, which is
held either by springs or a hydraulic system. This design helps in coarse crushing of moderately hard
to soft materials.
Hammer Crusher: In hammer crushers the hammers are attached to the rotor via pivots so that they
are deflected when they hit strong and particularly large stones. In most cases the crushing zone is
surrounded by grate bars so that fragments which are larger than the openings of the grating are
retained in the crushing zone. Huge hammer crushers with rotor diameters up to 3m are available
which have throughput of even 1500TPH. Although hammer crushers wear more quickly than impact
crushers, they can process moist materials more efficiently. Only soft to moderately hard materials can
be processed because of wear considerations. These crushers are simpler than jaw and cone crushers
and units with equivalent throughput are much smaller in size.

Impactor/Impact Breakers: - The Impactor or Impact Breaker or double impeller breaker crusher
uses the energy contained in falling stone, plus the power imparted by the massive impellers. Rock fed
into the breaker falls directly on to the impellers (which weigh up to 6.5 tons) and rotate away from
each other, turning up and outward, at speeds from 250 to 1000 RPM depending on the desired size of
finished product. Pieces of rock are sent crashing against steel breaker bars mounted in specific
positions around the breaking chamber or crash against other rocks hurtling through the chamber and
are further reduced without the use of extra horsepower. The stone falls again onto the impellers to
repeat the cycle until reduction is complete. Size is controlled by impeller speeds and the vertical and
horizontal spacing of adjustable breaker bars.
A horizontal shaft impact crusher comprises a crusher housing having an inlet for material to be crushed,
an outlet for material that has been crushed, hammer being mounted on a horizontal shaft in the crusher
housing and being operative for rotating around a horizontal axis, a curtain against which material
accelerated by the hammer may be crushed, and an adjustment device for adjusting the position of said
curtain relative to the hammer .The crusher housing is provided with at least two guide rails to which said
adjustment device is slid ably connected, retaining means which is arranged to hold, with a predetermined
holding force, said adjustment device in a crusher operation position relative to the guide rails ,said
adjustment device being movable along said guide rails from the crusher operation position and away
from the impeller in response to an excessive force being transferred from the curtain to the adjustment
device and exceeding the predetermined holding force.
Rotopoctor: Rotopoctor is an impact crusher in which the feed is reduced through the impact
imparted by a revolving manganese steel rotor, and manganese steel breaker plates which form its
outer housing. Feed up to 150 mm enters the rotor center, axially. The change in the rotor speed varies
the range of output size. The crushing chamber is designed to provide 90 impacts to the material
being crushed, which contributes to excellent particle size of the finished product.
2.2. Classification of crusher
A crusher can be classified depending on the size reduction factor as follows.
a) Primary crusher: - The raw material from mines is processed first in primary crushers. The input
of these crushers is relatively wider and the output products are coarser in size. Example - Jaw
crusher, Gyratory crusher, Impact Crushers, etc.
b) Secondary crusher: - The crushed rocks from primary crusher are sent to these secondary
crushers for further size reduction. Example:-reduction gyratory crusher, Cone crusher, disk
crushers etc.
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c) Fine crusher: - Fine crushers have relatively small openings and are used to crush the feed
material into more uniform and finer product. Example - Gravity stamp.
2.3. Types of impact stone crusher
These crushers involve the use of impact rather than pressure to crush materials. Here the material
is held within a cage, with openings of the desired size at the bottom, end or at sides to allow crushed
material to escape through them. Here the breakage can take place in a much shorter scale
compared to fragmentation process used in cone or jaw crushers. An impact stone crusher can be further
classified as Horizontal shaft impact stone crusher and vertical shaft impact stone crusher based on the
type of arrangement of the impact rotor and shaft.
2.3.1. Horizontal shaft impact stone crusher
These break rock by impacting the rock with hammers/blow bars that are fixed upon the outer edge of a
spinning rotor. Here the rotor shaft is aligned along the horizontal axis. The input feed material hits the
rotating hammers of the rotor and due to this sudden impact it breaks the material and further breaks the
material by throwing it on to the breaking bar/anvils. These have a reduction ratio of around 10:1 to
25:1 and are hence used for the extracted materials, sand, gravels etc.
2.3.2. Vertical shaft impact stone crusher
These crushers use a high speed rotor that has its axis along the vertical axis. The vertical-shaft impact
crusher can be considered a stone pump that can operate like a centrifugal pump. The material is
fed through the center of the rotor, where it is augmented to high speeds before being cleared through
openings in the rotor sideline. The material is crushed as it hits the outer body/ anvils at high speed and
also due to the head on head collision action of rocks. It uses the velocity rather than the surface
force as the active force to break the material fed. These have a comparative lower reduction ratio of
6:1 to 8:1 and hence are used generally for sand and gravels.
2.4. Advantages of the horizontal over Vertical shaft impact stone crusher
Hammers have four crushing positions to maintain a more constant gradation and greater top size
control.
Less capital outlay.
High degree of product size control
Long life of wear components.
Large feed port, deep crushing chamber, high reduction ratio(20:1)
Manganese steel flat hammer wear resistance, great impact force
Easy operation and maintenance

8

During the last 20 years, the production and use of building stone has steadily increased nationwide, and
today stone has reached a position as one of the nations most important mineral resources. For many
countries, export of stone has become a significant economic activity. For others, the recognition of local
sources of building stone has secured a steady supply of cheap and durable construction materials for
domestic purposes. At present, Ethiopias economic construction and rapid development enhances the
need of the gravel and aggregate for the construction site.
The two dominantly produced aggregates, light weight (namely pumice and scoria) and the normal weight
(basalt), do have different modes of productions. The normal weight coarse aggregates for the Ethiopian
construction sector are produced by both, traditional and modern means. Traditionally coarse aggregate is
produced by heating a stone at a higher temperature and crushing it by a hammer using a manual labor to
the required approximate sizes. Aggregates produced using such method are usually flaky (peeling) and
do not satisfy the grading requirements set by standard recommendation. Nevertheless, such aggregates
are used for construction in areas where aggregates crushing machine(s) is not available and quality
control is not a criteria in the execution of the work. In preparing crushing it manually by hammer which
consumes long time, take maximum money, need many human powers and has many injure on human
body. So these problems will be solved by designing of stone crusher.
On the other hand, the modern way of aggregate production requires aggregate crushing machines so that
the quarry is either drilled, blasted or dug with special mechanisms, fed to crushers, crushed, sieved and
separated according to their sizes. The different sizes commonly known as 01, 02, 03 and 04 are
stockpiled separately. Size 02 means aggregates having a maximum aggregate size of 20mm,while 01,
03, 04 has a maximum aggregate size of 10, 30 and 40 mm respectively. This method enables to
classify aggregates based on their maximum aggregate sizes and enable engineers to suggest unique
mix proportion to arrive at the required concrete quality production. Gravel/ aggregate that needed /
used as raw material for the construction of buildings, bridges, roads, rail ways, dams etc. are crushed by
stone crusher. For these purpose the design of stone crusher is needed.
2.5. Locally available types of stone
The most commonly available local coarse aggregates are obtained from normal weight crushed basaltic
stone and lightweight volcanic ash, which are a member of a family of igneous rock (scoria or pumice).[1]
a) Basalt
Basalts are dark colored, fine-grained extrusive rock. The mineral grains are so fine that they are
impossible to distinguish with the naked eye or even with a magnifying glass. They are the most
widespread of all the igneous rocks. Most basalt is volcanic in origin and was formed by the rapid cooling
and hardening of the lava flows. Some basalt is intrusive having cooled inside the Earth's interior.
9

b) Pumice
Pumice is a very light, porous igneous rock that is formed during volcanic eruptions. It is excessively
cellular, glassy lava, usually rhyolite in composition. It is usually white-gray to yellow in color, but may
be red, brown or sometimes black according to the mineral oxides or impurities it contains. Pumice is
bubble rich and therefore has very low density. Due to this low density, pumice is very light and can even
float in water. It has a bulk density of 500-900kg/m3. The varieties of pumice, which are not too weak
structurally, make a satisfactory concrete with a density of 700 to 1400kg/m3 and with good insulating
characteristics, but high absorption and high shrinkage characteristics.
c) Scoria (red ash)
Scoria is a volcanic cinder which generally has a rough surface and high porous nature, with its pores
chiefly in the form of vesicles instead of the more tube like, interconnected pores of the pumice. Scoria
varies in color often within the same cone and may be black, red, gray or brown in color. The black color
is mostly due to its high iron content while the red color is caused by oxidation of iron in the scoria,
which
might
have
happened because of rainfall during the eruption. Scoria aggregate is found
extensively in Ethiopia especially in the Great Rift Valley, which crosses the Northeastern part of the
country. It is mainly used as a base coarse material in road construction and as an aggregate in the
manufacturing of masonry blocks.
10
3. PRELIMINARY DESIGN
3.1. Concept development
It is the recommended that many options should be come up with different options before moving in to
other step. The generated concepts are based on the modification of the new ideas with the machine
component.
Concept I
In this concept we develop simple mechanism of the integrated components like circular shaft, rotor plate,
hammer, wedge and locking mechanism with grove.
Figure 2.1: Rotor assembly and housing/ casing of concept one

It consists of four hammer mounted on the shaft locked by wedge. Two rotor plate will be mounted at the
tip ends of the shaft and long hammer with locking wedge assembled together to operate. The anvils (the
stationary hammer) would be mounted on the casing (housing) of the crusher to crush the raw materials.
Concept II
In this concept the parts will be the same as the first concept and differentiated by the number of rotor
mounted on the shaft and hummer. The integrated components like hexagonal shaft, rotor plate, hammer,
wedge and locking mechanism with grove. It consists of four hammer (a number hammer will be needed
depending on the number of rotor plate mounted on the shaft) mounted on the rotor plate locked by
wedge, and this number of rotor plate assembled together to be mounted on the hexagonal shaft.
Figure 2.2: Rotor assembly and casing of concept two

11

On the assembly of rotor plate the hammers are not aligned on the same axis between the rotor plates.
The hexagonal shaft profile would replace the work of the locking key for the rotor plate with the shaft
and enables to transmit the rotary power from the motor between them.
The design concept of the anvils is individual, assembled on the casing and operate translational motion
which will helps to vary the size of aggregates.
Concept III
As we discuss in the previous concepts the same integrated parts of the components of the two concepts
would be selected to be assembled together and additionally to support the hammer for more strength the
supporting wedge will be added & more reliable locking mechanism for the translational motion of the
rotor plate along the shaft will be locked by bolt or key system.
The hammer will be inserted between the locking wedges and supporting wedge and locked by inserting
long small diameter shaft through the groove. Single long hammer will be assembled on the rotor plate
along which will connect the rotor plate.
a) Rotor assembly
b) general assembly
Figure 2.3: Rotor assembly and overall assembly of concept three

3.2. Concept evaluation and decision
From the concept developed, we try to compare them in terms of important points that will determine the
functionality of the machine. The evaluating system of the concepts is given from 1 to 3 grades.
NB: the evaluation grade will be as mentioned below
1-low grade
2-medium grade
3-high grade
12

Table 3.1 Concept evaluation and decision table
Criteria
Concept-I
Concept-II
Concept-III
Manufacturing cost
Material cost
Simplification
Durability
Reliability
Time to produce
Handling
Weight
Stability
Strength
Functionality
Mechanism
1.5
Efficiency
2.5
Total
23.5
25.5
33
Therefore, from the above evaluation table we can conclude that by referring to the total points of the
concepts, which satisfies our statement of problem to get best significance of the project, the 3rd concept
is selected to be designed.
3.3. Operational principle of the machine
Stone crusher machine crushes materials with impact force. When the materials enter the blow bar area,
they are crushed due to the high-speed impact of the blow bar and are thrown to the impact plates on the
rotor for secondary crush. Then the materials will be shot back to the blow bar again for the third crush.
This process repeats until the materials are crushed to the required size and discharged from the lower part
of the machine. Feed material drops through the feed opening on to enclosed rotor which, through
centrifugal force throws the material against stationary anvils when the rock impacts the anvils at 90
angle; it shelters along natural grain structures creating a uniform cubical product. Product output is easily
controlled by varying the rotor speed.
13
4. MATHEMATICAL SIMULATION
4.1. Application of law of conservation of moments to impact
The application of law of conservation of momentum is helpful in impact. Since, it can generalize some of
the overall effects of the process. Let consider a stationary object of mass m1 (mass of the stone), which
is struck by another object of mass m2 (mass of the rotating hammer) initially moving at a velocity of u2,
and consider that the two masses remain together after impact and move together after impact at a velocity
of V2. Then from conservation of momentum,
(
The initial velocity of the hammer and number of impact will be calculated from, respectively,
&
Weight of the particle to be crushed per second of each hammer can be found by
Let KE1= equal to the initial kinetic energy before impact and KE2 is equal to kinetic energy of the
combined mass after impact, then
The loss of kinetic energy is taken up as strain energy of the masses, heat and perhaps by permanent
deformation of the colliding objects. The above equation shows why small hammers at high velocities are
used in crushing processes where a maximum amount of fracture is required and why large hammers at
relatively slow velocities are used in pile driving where the object is to give the pile as much kinetic
energy as possible.
The application of the law of conservation of momentum to two objects colliding is quite straight forward
since the problem is concerned with the effects after impact, however, in crushing process the system may
change drastically if fracture takes place during impact. The impact process is not instantaneous and
during the process rotational kinetic energy of the impacting changes to strain energy, kinetic energy of
vibration of the hammer and stone masses as well as to other forms of energy. In this case it is difficult to
determine the distribution of initial kinetic energy to the elemental parts of the system and consequently
difficult to determine the loss of initial kinetic energy to other forms of energy. As a general rule,
however, the case of crushing may be considered analogous to the case forging in that light hammers at
high velocities would be advantageous. An objection may be raised to the above rule in that, in crushing
devices where impact is employed, the impacting medium will lose all its kinetic energy either by a single
Page 14
impact or a number of further impacts and so nothing would be gained by adjustment of the weights of the
impacting masses. The main object however, is to cause fracture and unless the impacts raise the strain
energy of the impacted material above a certain level, the energy input is lost in the form of heat and does
not contribute to the crushing process. If fracture is to be obtained by impact it is desirable for the
impacting masses to loss as much kinetic energy as possible during a single impact so that a maximum
amount of energy would be available for fracture. [15]
4.2. Static stresses and displacement
Under the static condition the stress values arising from impact and since the strain energy density in the
impacted object would, in general not constant throughout; the stress condition would be a better criterion
for predicting fracture than the total strain energy of the masses.
In static loading any change in applied force is so low compared to the velocity of stress propagation of
that the specimen may be considered to read just instantaneously at all points under the change in loading.
An analysis of the crack propagation equation illustrates the effect of cracking and shows how the crack
propagation velocities are dependent on the physical characteristics of the material through which the
crack are transmitted. [25]
The velocity of the crack propagation can be found by applying the equation of momentum,
Thus the velocity of crack propagation is dependent only on the characteristics of the material and is
independent of the applied load or force. [25]
4.3. Kinetics and kinematics of hammer rotation
4.3.1. Kinetics: Rotation of the rotor assembly
Considering the assembly of the rotor only for single particle of input product and hammer, the following
mathematical simulations are derived.
When a rotor assembly (rigid body) rotates about a fixed axis, all points other than those on the axis
moves in concentric circle about the fixed axis. Thus for the rigid body rotating about a fixed axis normal
to the plane of the figure through O. any point such as point A moves in a circle of radius l.
Page 15
Figure 4.1: A single particle just after the rotor bar of a hammer crusher
4.3.2. Kinematics: Energy loss during impact
Impact phenomenon is almost always accompanied by energy loss, which may be calculated by
subtracting the kinetic energy of the system just after impact from that just before impact. Energy is lost
through the generation of heat during the localized inelastic deformation of the material, through the
generation and dissipation of elastic stresses waves within the bodies, and through the generation sound
energy. [24]
The Basic Assumptions made here:
Rotor mass is much greater than mass of single particles in the feed
Before impact, linear velocity of the crushing bar is much more important than the particle velocity.
For the particle it will be determined form free falling at some height.
It is also assumed that most particles enter into the collision with the rotor bars in the median region of
their impact areas with the hammer
Considering the conservation of linear momentum, before and after the impact the energy/ mass is given
as
Initial kinetic energy of the system before impact is
Final kinetic energy of the system is,

(
The energy loss will be given as, crushing effect derived from subtracting the initial from the final kinetic
energy
Page 16
The intensity of dynamic stress induced by the rotor and by the impact into the fixed surface i.e. the
breaking bars/wall can be calculated as
The dynamic crushing force (centrifugal force developed) required to crush the basalt can be found by
considering the weight of input product and initial velocity of the particle.
&
4.4. Parametric mathematical simulation
The initial design consideration
Capacity of the feed rate =180TPH(50kg/s)
Input product specification=basalt, pumice and scoria
Number of hammers = 4
Product output size = up to 40mm
Top feed size = 500x1000mm2
Falling distance of particle =600mm
Assume mass of hammer is greater than(>>)mass of particle (10m1=m2)
Revolution = 300rpm
Volume of particle = 2.7x10-5 m3
From the feed rate 180TPH and revolution of 300rpm the number of impact will be calculated as
The initial velocity of the particle would be found from

(
Tonnage per impact is given by
The initial velocity of the particle would be found from
The final velocity of the rotor and the particle stick together is given by
(
Page 17
The kinetic energy of the system before impact and after impact will be given as
Crack propagation velocity is given by
The dynamic stress will be given as

(
) (
Torque required will be given by
Page 18
5. MATERIAL SELECTION AND DETAIL DESIGN

5.1. Design of hammer
Hammers can be made using different sections like, I section, T section, S section, cylindrical bars,
rectangular bars etc. Due to the shape of the hammers decides the impacting capacity as well as the
strength of the crusher, in order to resist with this property for our design we are dedicated to use
rectangular hammers. Hammers are mounted on the rotor plates and for locking mechanism sliding
method through grooved one are used.
5.1.1. Material selection and stress analysis of hammer
For design of a hammer Manganese steel is selected due to its high impact strength and resistance to
abrasion once in its work-hardened state. Manganese steel is alloy steel containing 0.8 to 1.25% carbon,
with 11 to15% Manganese.
Manganese steel is unique non-magnetic steel with extreme anti wear properties. The material is very
resistant to abrasion and will achieve up to three times its surface hardness during conditions of impact
without any increase in breathlessness which is usually associated with hardness. It improves the strength
of the steel in both the hot rolled and heat treated condition. The principal use of manganese steel is in
machinery parts subjected to severe wear. These steels are all cast and ground to finish. This allows
manganese steel to retain its toughness, having a rectangular cross section.
Mechanical properties of manganese steel (40C15S12)
Elastic Modulus=165Gpa
Mass Density=7800kg/m3
Tensile Strength=600Mpa
Yield Strength=330Mpa
Factor of safety=4
5.1.2. Dynamic condition of stress analysis
The hammers are subjected to: Shear force (are unaligned forces pushing one part of a body in one direction, and another part the
body in the opposite direction) at the point of fixation,
Centrifugal force due to rotation(dynamic crushing force) and
Bending force due to striking of the material
Page 19
When a sudden impact is observed by the hammers due to input feed striking over, it experiences an
impact load. A load is said to be an impact load, when it is applied with some initial velocity. The effect of
impact loads differs appreciably from that of the static loads as with a suddenly applied load, both the
magnitude of the stresses produced and resistance properties of materials are affected.
The critical concept that has to be observed is that, first, the design of hammer is under its consideration of
dynamic status rather than the static one, since it is subjected to rotational motion dynamic stress will be
produced during the impact due to the crack propagation velocity of the input product particle and the
initial velocity of the hammer. This will lead us to design the hammer under the consideration of dynamic
condition. Secondly, the deflection of the hammers has to be minimized as much as possible to get the
effective required efficiency of the rotor rotation.
From general equation of deflection of statically indeterminate, the equivalent force related to the moment
produced by external force as described below.
As the particle falls from the distance h, the potential energy (mgh), of the block is transformed into
kinetic energy; as a result of impact kinetic energy in turn is transformed to strain energy. [5]
But the total distance through which the stone drops is actually
where
is maximum deflection
at the end of the hammer. Thus, the more accurate expression for strain energy is given as:
(
The strain for the hammer is given in terms of the equivalent static force produced in the hammer. This is
given by:
By combining the deflection and strain energy equation:
Data for design:

Length of hammer tmmx250mmx1000mm
The particle assumed to be fall from height of 600mm
The hammer is considered to act like as a cantilever been with 1/3 is inserted into rotor plate slots for
fixation purpose
Page 20
a) When the cantilever blow bar is subjected to a concentrated load at the tip of the
cantilever(hammer)
a) Cantilever beam
b) Shear diagram
c) moment diagram
Figure 5.1: cantilever beam subjected to concentrated load at the tip

(
and
And solving the equations simultaneously for
W=81.67N, l=150mm
Substituting in the maximum stress induced at the end of the hammer bar
(
(
Hence
) ( )
Design for strength recommends us to consider
((
and
This value will be iterated to the standard one and will be

Page 21
Using the deflection formula

(
b) Assuming the tonnage is concentrated falling from a distance of 600mm and then
applying impact equation
a) Cantilever beam
b) Shear diagram
c) moment diagram
Figure 5.2: cantilever beam subjected to concentrated load at the middle

Maximum bending moment I given by
(
At
c) Assuming the force is to be uniformly distributed load taking from a height h

From our specification and calculation above we have
W=81.67N, l=150mm
a) Cantilever beam
b) Shear diagram
c) moment diagram
Figure 5.3: cantilever beam subjected to concentrated load distributed
Page 22
But the maximum allowable stress is which is greater than the maximum induced stress. So the design is
safe for this condition also.
5.1.3. Using Strain Energy method
Strain Energy of the member is the internal work done in deforming the body by the action of externally
applied forces. This energy in elastic bodies is known as elastic strain energy: when a body is loaded
within elastic limit, it changes its dimensions and on the removal of the load, it regains its original
dimensions. So long as it remains loaded, it has stored energy in itself. The strain energy is always capable
of doing some work. [5]
It is an important property of a material and gives capacity of the material to bear impact or shocks.
Design of hammers considering ending loading with fatigue
Often, machine members are found to have failed under the action of repeated or fluctuating stresses; yet
the most careful analysis reveals that the actual maximum stresses were well below the ultimate
strength of the material, and quite frequently even below the yield strength. The most distinguishing
characteristic of these failures is that the stresses have been repeated a very large number of times. Hence
the failure is called a fatigue failure. So fatigue loading is not applicable in this case.
Let use Strain Energy method and approximating the loading to be a static one.
Since the hammer is rectangular cross section it might be subjected plane shearing stresses. The strain
energy density at a given point can be expressed as
Figure 5.4: strain energy diagram
Strain energy density is equal to the area under the shearing stress strain diagram
Where G modules of rigidity

Page 23
The value of the strain energy of a body subjected to plane shearing stresses can be obtained by
and
The strain energy due to normal stress
) (
Now setting
Performing integration and substituting for

*(
dv=wdydx
we have
)+
The total strain energy of the hammer is

Hence
And factorizing for Ur
(
From
Solving for
(
Since the value of
and substituting into

) (
(
is considered to be very small due to impact we can eliminate it.
Now substituting datas for the design

W=81.87N,
h=0.6,
(
E=165Gpa,
G=80000kpa
)
(
(
(
)(
)(
)
)
Page 24
5.2. Design of rotor plate

Rotor plate is used to hold hammers locked on it with the locking wedge in order to transmit the torque
from the shaft to the hammer and mounted on shaft. The translational motion of the rotor over the shaft is
controlled with snap rings and locked by key to receive torque from shaft.
5.2.1. Material selection and stress analysis
Since the rotor plate is subjected to transmit maximum torque which will result in the dynamic centrifugal
force, which will cause crushing process it has to be of a material which has high strength and relatively
toughness to resist the impact load, like plain carbon steel material.
Mechanical properties of plain carbon steel
Yield Strength=220.59Mpa
Shear Modulus =79Gpa
Factor of safety=6
Tensile Strength=399.83Mpa
The rotor plats have to be with stand the centrifugal crushing force. Due the centrifugal force the rotor
plate is subjected to the normal bending stress and shearing stress.
a) Design for normal bending stress
The allowable normal and shear stress of the material is given by considering the factor of safety
Slot area on which pressure will exerted is calculated as, let the thickness of the rotor is assumed to be
100mm, in terms of dynamic condition let assume the dynamic condition factor of 3.
The stress produced due to the centrifugal force area on which the force is transmitted to the rotor plate is
assumed as a cantilever beam.
Page 25
Figure 5.5: Bending part of rotor plate
Let assume the width of the plate 100mm
Now, since the induced bending stress is less than the allowable stress of the material the design of this
rotor in terms of strength is appropriate or generally it is safe from bending.
b) Design for shearing strength
Cantilever beam of rectangular cross section of width b and depth of h subjected to load, i.e. centrifugal
force, at its free end. Since the shear in the beam is constant and equal to the centrifugal force in
magnitude. The shear stress induced in the beam is given by
From the above analysis we can generalize that the design is safe from shearing, since the maximum shear
stress produced in the rotor plate is less than the allowable shear stress of the plain carbon steel.
5.3. Design of Flywheel
A flywheel is an inertial energy-storage device. It absorbs mechanical energy and serves as a reservoir,
storing energy during the period when the supply of energy is more than the requirement and releases it
during the period when the requirement of energy is more than the supply.
The main function of a fly wheel is to smoothen out variations in the speed of a shaft caused by torque
fluctuations. Stone crushers are the systems that have fly wheel. Flywheel absorbs mechanical energy by
increasing its angular velocity and delivers the stored energy by decreasing its velocity.
When the power shortage and the angular of the flywheel reduced, the flywheel of the stone crusher will
release the energy to increasing the effective power to broken material and to improve the efficiency of
Page 26

the crushing process. Due to the stone crusher have two conditions, working and idle, so the load on the
motor is very uneven. In order to reduce this imbalance load, both ends of the eccentric shaft have set up
flywheel and pulley. Of course the stone crusher wheel is very important for the stone crusher.
The flywheel often made by cast iron or steel. Of all the cast materials, gray cast iron is the most widely
used. This is because it has a very low cost, is easily cast in large quantities, and is easy to machine. In
addition to a high carbon content (over 1.7 percent and usually greater than 2 percent),cast iron also has
a high silicon content, with low percentages of sulfur, manganese, and phosphorus.
Due to its high density, low cost and excellent machinability, gray cast iron ASTM 30 is used as the
flywheel material. [17]
Properties of gray cast iron
Material, class, specification Gray cast iron, FG350
Ultimate strength
Tension, Sut=350Mpa; Shear Sut=1080Mpa
Torsional/ shear strength = 403Mpa

Modulus of elasticity Tension, E=140Gpa
Density =7510Kg/m3
Poissons ratio = 0.23
For the material in terms of factor of safety, the maximum allowable stress is
a) Power consumption for design specification

Speed of shaft N1=300rpm
Power used to drive the shaft
(
Coefficient of fluctuation for crusher machine speed is tabulated in table and is equal to Cs =0.2
b) Speed fluctuation and its coefficient
The change in the shaft speed during a cycle is called the speed fluctuation. We can normalize this to a
dimensionless ratio by dividing it by the average or nominal shaft speed (
(
mean).
The angular speed of shaft is obtained as follows
Page 27

(
The difference between the maximum and minimum speeds during a cycle is called the maximum
fluctuation of speed. The ratio of the maximum fluctuation of speed to the mean speed is called coefficient
of fluctuation of speed.
This coefficient is a design parameter to be chosen by the designer. The smaller this chosen value, the
larger the flywheel have to be and more the cost and weight to be added to the system. However the
smaller this value more smoother the operation of the device
c) Coefficient of Fluctuation of Energy
It is the ratio of the maximum fluctuation of energy to the work done per cycle. It is usually denoted by
mathematically calculated as follows;
The coefficient of fluctuation of energy
Use 0.1 for coefficient of fluctuation energy for crushing machine and determine the maximum fluctuation
energy.
The work done per cycle may also be obtained by using the following relation:
The mean torque on the shaft,
Page 28
d) Design Equation
The kinetic energy
in a rotating system (flywheel)
( )
. .. (1)
Hence the change in kinetic energy of a system can be given as i.e. as the speed of the flywheel
changes from
to
, the maximum fluctuation of energy.
)(
. (2)
Radius of gyration: The distance from an axis at which the mass of a body may be assumed to be
concentrated and at which the moment of inertia will be equal to the moment of inertia of the actual mass
about the axis, equal to the square root of the quotient of the moment of inertia and the mass. Where k is
radius of gyration and is given by
Therefore,
) =
Kg
)
Substituting the values from our specification Energy Stored in a Flywheel as the angular speed varies
from minimum to maximum.
Thus the mechanical efficiency of the system is
e) Cross-sectional dimensions of the flywheel rim

Considering the cross-section of the rim as rectangular and assuming the width of rim equal to twice the
thickness of rim.
Cross-sectional area of rim,
Page 29
Knowing the ratio of b/t which is usually taken as 2 we can substitute for b=2t
Thickness of the rim

The width of the rim is
Cross-sectional area of the rim
f) Stresses in a Flywheel Rim

A flywheel consists of a rim at which the major portion of the mass or weight of flywheel is concentrated,
a boss or hub for fixing the flywheel on to the shaft and a number of arms for supporting the rim on the
hub.
The following types of stresses are induced in the rim of a flywheel:
Tensile stress due to centrifugal force and
Tensile bending stress caused by the restraint of the arms
Tensile stress due to the centrifugal force
The tensile stress in the rim due to the centrifugal force, assuming that the rim is unstrained by the arms, is
determined in a similar way as a thin cylinder subjected to internal pressure.
Figure 5.6: Geometry of flywheel rims

Check for centrifugal stress;
We know the peripheral velocity of the rim
Page 30

Centrifugal stress induced in the rim
(
g) Tensile bending stress caused by restraint of the arms

The tensile bending stress in the rim due to the restraint of the arms is based on the assumption that each
portion of the rim between a pair of arms behaves like a beam fixed at both ends and uniformly loaded.
Section modulus
Bending stress in the rim is given as the follows;
(
Where n= Number of arms. The number of arms is usually 6. Sometimes the arms may be 8, 10 or 12 for
very large size flywheels. So we select number of arms to be 6 for our design.
Is the mean radius
So the total stress on the rim is
h) Stresses in Flywheel Arms

The following stresses are induced in the arms of a flywheel.
1. Tensile stress due to centrifugal force acting on the rim.
2. Bending stress due to the torque transmitted from the rim to the shaft or from the shaft to the rim.
1. Tensile stress due to centrifugal force acting on the rim.
Due to the centrifugal force acting on the rim, the arms will be subjected to direct tensile stress whose
magnitude is same as discussed in the previous article.
Therefore tensile stress in the arms,
2. Bending stress due to the torque transmitted from the rim to the shaft or from the shaft to the
rim.
Due to the torque transmitted from the rim to the shaft or from the shaft to the rim, the arms will be
subjected to bending, because they are required to carry the full torque load. In order to find out the
maximum bending moment on the arms, it may be assumed as a cantilever beam fixed at the hub and
carrying a concentrated load at the free end of the rim as shown in Fig below
Page 31
Figure 5.7: Flywheel cantilever beam

Bending stress in arms
(
Total tensile stress in the arms at the hub end
Note; the total stress on the arms should not exceed the allowable permissible stress.
The diameter of hub is usually taken as twice the diameter of shaft and length from 2 to 2.5times the shaft
diameter. It is generally taken equal to width of the rim(
The outer diameter of the hub

Therefore, radius of the hub is
The maximum torque acting on the shaft is as calculated above
Section modulus
(
Total tensile stress in the arms at the hub end
Cross sectional dimensions of elliptical arms

Let assume: a1=major axis
b1=0.5a1 minor axis
Page 32

l) Design of flywheel shaft, hub and key
The diameter of shaft of fly wheel is obtained from the maximum torque transmitted. Since the maximum
torque on the shaft is twice the mean torque the maximum torque acting on the shaft,
Torque acting on the shaft is given by:
Shaft diameter
And the diameter of the hub is made equal to twice the diameter of shaft and length of hub is equal to
width of the rim. [17] Therefore,
Diameter of hub is= 2D=2x75mm=150mm
Length of hub is =l=62mm
a) Dimension for key
The standard dimensions of rectangular sunk key for a shaft of diameter 75mm are as follows as;
Width = 22mm
Thickness= 14mm
Key depth t1= 8.5mm (in the haft)
t2=5.5mm (in the hub)
Length of the key is 63-250mm
b) Considering shearing of the key,
Shearing strength (or torque transmitted) of the key
( )
And torsional shearing strength (or torque transmitted) of the shaft

(
( )
Equating (1) and (2) and solving for l=100.355mm

Generalizing to even number =105mm
Now considering crushing strength (Torque transmitted) of the key,
( )
Now considering equation (2) and (3) and solving for l

Page 33
The greater length would be selected.

5.4. Design of the pulley
The pulleys are used to transmit power from one shaft to another by means of flat belts, V-belts or ropes.
Since the velocity ratio is the inverse ratio of the diameters of driving and driven pulleys, therefore the
pulley diameters should be carefully selected in order to have a desired velocity ratio. The pulleys must be
in perfect alignment in order to allow the belt to travel in a line normal to the pulley faces.
The pulleys may be made of cast iron, cast steel or pressed steel, wood and paper. The cast materials
should have good friction and wear characteristics. [17]
Cast Iron pulleys
The pulleys are generally made of cast iron, because of their low cost. The rim is held in place by web
from the central boss or by arms or spokes. The arms may be straight or curved and the cross-section is
usually elliptical.
The cast iron pulleys are generally made with rounded rims. This slight convexity is known as crowning.
The crowning tends to keep the belt in center on a pulley rim while in motion. The crowning may be 9
mm for 300 mm width of pulley face. The cast iron pulleys may be solid or split.
When it is necessary to mount a pulley on a shaft which already carrying pulleys etc. or have its ends
swelled, it is easier to use a split-pulley. There is a clearance between the faces and the two halves are
readily tightened upon the shafts by the bolts. A rectangular sunk key is used for heavy drives.
Steel pulleys
Steel pulleys are made from pressed steel sheets and have great strength and durability. These pulleys are
lighter in weight (about 40 to 60% less) than cast iron pulleys of the same capacity and are designed to run
at high speeds. They present a coefficient of friction with leather belting which is at least equal to that
obtained by cast iron pulleys.
Wooden Pulleys
Wooden pulleys are lighter and possess higher coefficient of friction than cast iron or steel pulleys. These
pulleys have 2/3rd of the weight of cast iron pulleys of similar size. These pulleys are made both solid or
split with cast iron hubs with keyways or have adjustable bushing which prevents relative rotation
between them and the shaft by the frictional resistance set up. These pulleys are used for motor drives in
which the contact arc between the pulley face and belt is restricted.
Page 34

Paper pulleys
Paper pulleys are made from compressed paper fiber and are formed with a metal in the center. These
pulleys are usually used for belt transmission from electric motors, when the center to center shaft
distance is small.
5.4.2. Stress analysis
For the design of impact stone crusher pulleys material is cast iron.
Procedures adopted for the design of cast iron pulleys are:
i) Dimensions of pulleys
The diameter of the pulley (D) may be obtained either from velocity ratio consideration or centrifugal
stress consideration. We know that the centrifugal stress induced in the rim of the pulley,
From selection of V-grooved pulley

The mean revolution N=273RPM,
(
)(
Now centrifugal stress will be;
a) Face width
From width of the belt, the width of pulley or face width of the pulley (B) is:
The dimension for standard V-grooved pulley is shown in table from which we find that for C type belt.
Figure 5.8: Cross section of v grooved pulley
Now the face width of the pulley

Page 35

(
The following are the width of V-belt of cast iron and mild steel pulleys in mm: 16, 20, 25, 32, 40, 50, 63,
71, 80, 90, 100, 112, 125, 140, 160, 180, 200, 224, 250, 315, 355,400, 450, 560, and 630.
So from standard width of the pulley, B =224mm
b) The thickness of the pulley rim (t) varies from:
And
the diameter of the
pulley (d) =200mm. So thickness of the pulley;
c) Dimensions of arms
The number of arms may be taken as 4 for pulley diameter from 200 mm to 600 mm
The cross-section of the arms is usually elliptical with major axis (a) equal to twice the minor axis (b).
The cross-section of the arm is obtained by considering the arm as cantilever i.e. fixed at the hub end and
carrying a concentrated load at the rim end. The length of the cantilever is taken equal to the radius of the
pulley. It is further assumed that at any given time, the power is transmitted from the hub to the rim or
vice versa, through only half the total number of arms.
Where
T=Torque transmitted,
R=Radius of pulley=100mm
n = Number of arms=4
( )
The arms are tapered from hub to rim. The taper is usually
5.5. Design of belt drive
A belt provides a convenient means of transferring power from one shaft to another. Belts are frequently
necessary to reduce the higher rotational speeds of electric motors to lower values required by mechanical
equipment. The belt driver relies on frictional effects for its efficient operation. When the belt connecting
two pulleys is stationary the tensions in the two portions of the belt are equal but when torque is applied to
the driving pulley, one portion of the belt is stretched and the other portion becomes slack. The procedure
Page 36

for selecting a V-belt drive is dependent on the motor horse power and the speed (rpm) rating. V-belts are
rated from class A to E (appendix16).
The amount of power transmitted by belt depends upon the following factors:
The velocity of the belt.
The tension under which the belt is placed on the pulleys.
The arc of contact between the belt and the smaller pulley.
The conditions under which the belt is used.
5.5.1. Selection of a belt drive

Following are the various important factors upon which the selection of a belt drive depends:
Speed of the driving and driven shafts
Speed reduction ratio
Power to be transmitted
Centre distance between the shafts
Position of shaft
Space available and
Service conditions.
5.5.2. Types of belt drives

Depending on speed the belt drives are usually classified into the following three groups:
Light drives: These are used to transmit small powers at belt speeds up to about 10 m/s as in
agricultural machines and small machine tools.
Medium drives: These are used to transmit medium powers at belt speeds over10 m/s but up to 22
m/s, as in machine tools.
Heavy drives: These are used to transmit large powers at belt speeds above 22 m/s as in compressors,
crushers and generators.
Based on shape belts can be classified as:
Flat belt. The flat belt is mostly used where a moderate amount of power is to be transmitted, from
one pulley to another when the two pulleys are not more than 8 meters apart.
V-belt. The V-belt is mostly used where a great amount of power is to be transmitted, from one pulley
to another, when the two pulleys are very near to each other.
Circular belt or rope. The circular belt or rope is mostly used where a great amount of power is to be
transmitted, from one pulley to another, when the two pulleys are more than 8 meters apart.
Page 37

If a huge amount of power is to be transmitted V-belts or circular belts with a number of grooves are used.
Then a belt in each groove is provided to transmit the required amount of power from one pulley to
another.
Since huge amount of power transmitted by horizontal shaft impact stone crusher V-belt type has been
selected.
5.5.3. Advantages of V-belt Drive over Flat Belt Drive
The V-belt drive gives compactness due to the small distance between centers of pulleys.
Since the V-belts are made endless and there is no joint trouble, therefore the drive is smooth.
It provides longer life, 3 to 5 years.
It can be easily installed and removed.
The operation of the belt and pulley is quiet.
The high velocity ratio (maximum 10) may be obtained.
5.5.4. Belt Materials
The material used for belts and ropes must be strong, flexible, and durable. It must have a high coefficient
of friction.
The belts, according to the material used, are classified as follows:
1. Leather belts. The most important material for flat belt is leather. The best leather belts are made from
1.2 meters to 1.5 meters long strips cut from either side of the back bone of the top grade steer hides.
2. Cotton or fabric belts. Most of the fabric belts are made by folding cotton duck to three or more layers
(depending upon the thickness desired) and stitching together. They are impregnated with some filler like
linseed oil in order to make the belt water-proof and to prevent injury to the fibers. The cotton belts are
cheaper and suitable in warm climates, in damp atmospheres and in exposed positions.
3. Rubber belt. The rubber belts are made of layers of fabric impregnated with rubber composition and
have a thin layer of rubber on the faces. These belts are very flexible but are quickly destroyed if allowed
to come into contact with heat, oil or grease. One of the principle advantages of these belts is that they
may be easily made endless.
4. Balata belts. These belts are similar to rubber belts except that balata gum is used in place of rubber.
These belts are acid proof and water proof and it is not affected by animal oils or alkalis. The balata belts
should not be at temperatures above 40C because at this temperature the balata begins to soften and
becomes sticky. The strength of balata belts is 25 per cent higher than rubber belts.
Page 38

a) Working stresses in belts
The ultimate strength of balata belt varies from 21 to 35 MPa and a factor of safety may be taken as 8 to
10. However, the wear life of a belt is more important than actual strength. It has been shown by
experience that under average conditions an allowable stress of 2.8 MPa or less will give a reasonable belt
life. An allowable stress of 1.75 MPa may be expected to give a belt life of about 15 years.
b) Power transmitted by belt
According to R.s.Khurmi and J.k.Gupta, (2005), the power transmitted by belt is given by
(
But,
)
)
( )
Also
Where:
= Groove semi-angle;
=Angle of lap;
=Coefficient of friction.
The coefficient of friction for balata rubber belt on cast iron or steel operating on dry surface is 0.32. The
angle of lap for open V-belt drive is given as:
(
Also
c) Center distance of belt

The maximum center distance of belt in use depends on the size of the two pulleys and is given as:
(
d) Length of belt
Belt length can be calculated if the diameters of both the bigger pulley and the smaller pulley and the belt
center distance are known:
(
e) Centrifugal action
The belt is having some mass and as it passes over the pulley it moves over a circular path. Hence, it is
subjected to centrifugal forces.
Considering the small element of length R
and mass m per unit length, the centrifugal force on the
element is;
(
)
Page 39

If
is the tension in the belt due to the centrifugal effect, then equilibrium equation gives
Or
Where V is the belt velocity and m is the mass of the belt per unit length.
f) Coefficient of friction between belt and pulley
The coefficient of friction between the belt and the pulley depends upon the following factors:
The material of belt
The material of pulley
The slip of belt; and
The speed of belt
From table appendix 16 balata v-belt type with cast iron pulley material of dry type which has coefficient
of friction ( )=0.32 has been selected.
g) Design specification for V-belt derive
Power to be transmitted 41.3 KW,
Input speed (N1) =700rpm (increased by 35% of output speed)
Output speed (N2) =246rpm
Diameter of large pulley (D2) =200mm
The included angle (
)for the V-belt is usually from 30 to 40. For our design we have been taken
38
Balata belt material is used
Density of belt material (Balata) ( )
Allowable stress of belt material ( )
Coefficient of friction between belt and pulley ( )
Center distance of the belt (X) =500mm
Cross sectional area of the belt (A) =308mm2
Speed ratio of the V-belt can be calculated;
Page 40
Figure 5.9: Geometry of angle contact for both pulleys.

The angle of contact for both pulleys from geometry
(
)
(
Now the angle of contact on small pulley

(
Angle of contact on larger pulley (
)
(
Mass of the belt per meter length will be

Mass (m) =Area (A)*center distance(X)*density( )
Now centrifugal tension ( )
And maximum tension in belt;

Total tension in belt;
(
We know that
( )
( )
Page 41
Power transmitted per belt

)
P=(
(
Number of V-belts (n)
Length of each belt (L);

(
(
)
)
(
(
)
)
5.6. Design of driven pulley

5.6.1. Shaft design
Let D=diameter of driven pulley shaft
We know that torque transmitted by the driven pulley shaft
Since the driven pulley is overhang and the distance of the center from the nearest bearing is 200mm,
therefore bending moment on the shaft due to the pull on the belt
(
Number of belts=4
(
Equivalent twisting moment
Page 42

5.6.2. Dimensions of hub of the pulley
The diameter of the hub (d1) in terms of shaft diameter, D=65mm from shaft design may be fixed by the
following relation:
(
The diameter of the hub should not be greater than 2d.

The length of the hub,
The maximum length of the hub is (B) but it should not be more than width of the pulley
5.6.3. Key selection for the pulley

The standard dimensions of rectangular sunk key for a shaft of diameter 65mm are as follows as;
Width = 18mm
Thickness= 11mm
Key depth t1= 6.6mm (in the shaft)
5.6.4. Considering shearing of the key,
( )

(
( )

Generalizing to even number =95mm
( )
Page 43

5.7. Design of shaft
A shaft is a rotating member, usually of circular cross section, used to transmit power or motion. It
provides the axis of rotation, or oscillation, of elements such as pulleys, flywheels, rotor plate assembly,
controls the geometry of their motion. Shafts are the elements that support rotating parts like rotor
assembly, flywheel and pulleys and in turn are themselves supported by bearings resting in the rigid
machine housings. The shafts perform the function of transmitting power from the motor to rotor. Thus,
they are subjected to torque due to power transmission and bending moment due to reactions on the
members that are supported by them. Shafts are to be distinguished from axles which also support rotating
members but do not transmit power. Axles are thus subjected to only bending loads and not to the torque.
It have circular cross-section and could be solid. The shafts are classified as straight, cranked, flexible or
articulated. Straight shafts are commonest to be used for power transmission. The parts carried by shaft
are fastened to them by means of keys or snap ring and for this purpose the shaft is provided with key and
snap ring ways. The bearings that support the shafts may be of sliding contact or rolling contact type.
Deflection is not affected by strength, but rather by stiffness as represented by the modulus of elasticity,
which is essentially constant for all steels. For that reason, rigidity cannot be controlled by material
decisions, but only by geometric decisions.
Shaft material would be required to possess;
High strength,
Low notch sensitivity,
Ability to be heat treated and case hardened to increase wear resistance of journals, and
Good machinability.
Shafts could be made in mild steel, carbon steels or alloy steels such as nickel, nickel chromium or
chrome-vanadium steels.
Heavily loaded shafts are often made in alloy steels which because of their high strength would result in
smaller diameters. These steels are amenable to heat treatment and especially high wear resistance in
journal is obtainable by case hardening treatment. Diameters larger than 125 mm are regarded as large in
this respect. The forged shafts are subsequently machined to size. Steel castings are also used as shaft
material and their strength is comparable to mild steel.
The following stresses are induced in the shafts:
Shear stresses due to the transmission of torque (i.e. due to torsional load).
Page 44

Bending stresses (tensile or compressive) due to the forces acting upon machine elements like
hammer, wedges etc. as well as due to the weight of the shaft itself.
Stresses due to combined torsional and bending loads.
a) Maximum permissible working stresses for transmission Shafts
According to American Society of Mechanical Engineers (ASME) code for the design of transmission
shafts, the maximum permissible working stresses in tension or compression may be taken as;
(a) 112 MPa for shafts without allowance for keyways.
(b) 84 MPa for shafts with allowance for keyways.
The maximum permissible shear stress may be taken as
(a) 56 MPa for shafts without allowance for key ways.
(b) 42 MPa for shafts with allowance for keyways.
A shaft with key ways used for horizontal shaft impact stone crusher
It is not necessary to evaluate the stresses in a shaft at every point; a few potentially critical locations will
suffice. Critical locations will usually be on the outer surface. [20]
Possible Critical Locations, axial locations where:
The bending moment is large and/or
The torque is present, and/or
Stress concentrations exist.
b) Shaft design specification
Shaft material is AISI 1020 steel
Elastic Modulus = 200Gpa
Poissons Ratio = 0.29N/A
Shear Modulus = 77Gpa
Density = 7900kg/m3
Tensile Strength= 420.51Mpa
Yield Strength = 351.57Mpa
Power is constant = 41.3KW
Allowable shear stress of shaft material () = 42Mpa
By relating volume and their density formula for calculating the mass of each parts which will be mounted
on shaft, namely: - mass of hammer, rotor, locking wedge and supportive wedge
Page 45
Using the above formula the following value would be calculated,

Mass of four hammer =86.4Kgx4=345.6Kg
Mass of rotor plate=77.15Kgx5=385.75Kg
The total weight of the hammer and the rotor on the shaft is
(
Figure 5.10: total weight on the shaft
Taking moment at B;
(
( )
)
(
From equation the above equation
Now to draw a shear and moment diagram, let find the shear force and moment at point A, B, C, D and its
midpoint.
At point A and D, V = 0, M = 0
At point B, V = 126N, M = 37.8Nm
At midpoint of the distributed V = 1768.2N, M = 1145.035Nm
At point C, V = 350N, M = 63.35Nm
Page 46
a) Shear diagram
b) bending moment diagram
Figure 5.11: shear and bending moment diagram

So the maximum bending moment will be at the mid of the distributed force
M = 1145.035Nm
Considering notch sensitivity and stress concentration
Let assume D/d = 1.1
All fillet radiuses is 3mm
r/d = 0.046
Kt and Kts from graph at r/d, D/d and Sult
Kt = 1.8 = Kf and Kts = 1.4 = Kfs
The endurance limit for steel can be calculated as
Se= 0.5 Sult
for Sult < 1400Mpa
= 700 MPa for Sult > 1400 MPa
Stress concentration factors would be calculated as

ka = aSutb
the values of a and b could be found (machined) from appendix table 6
a = 4.51
b = -0.265
Kb = 1.51d-0.157
and Ka = 0.9096
51 < d < 254mm
Kb = 0.64
Kc = Ke = Kf = 1(refer appendix 5, 7, 8, 9, 10, 11, and 12 for the endurance limit modification
factor)
( )
(
-)
Substituting the values

Page 47
{
,
})
From the standard shaft diameter
5.7.3. Selection of key for shaft

A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley to connect these
together in order to prevent relative motion between them. It is always inserted parallel to the axis of the
shaft. Keys are used as temporary fastenings and are subjected to considerable crushing and shearing
stresses. A keyway is a slot or recess in a shaft and hub of the pulley to accommodate a key. Different
types of keys are available, the choice of which is dependent on power requirements, tightness of fit,
stability of connection and cost. For a light transmission, a set screw may be employed. But for this work,
a flat key of rectangular type was adopted, as this is used where added stability is desired. [6]
a) Specification for selection of key
From design data handbook, for rectangular key, we find the following dimension based on diameter of
shaft (80mm);
Width of the key, W=25mm
Thickness of the key, t=14mm
The length of key is given between 80-320mm, since the key is used to lock the rotor over the shaft key
length is equal to the width of rotor, 100mm
Key depth
t1= 9mm (in the haft)

Key material is mild steel and its property
Shearing stress( )=42Mpa
Crushing stress (
The length of the key is obtained by considering the key in shearing and crushing.
b) Considering shearing of the key,
( )

(
( )

Page 48

Generalizing to even number 110mm
( )
The greater length would be selected.

5.8. Selection of bearing
Rotating shafts are required to be supported at suitable places. The mechanical device which can take up
the load and support the shaft called the bearing. The bearing is so named because the surface of support is
subjected to a bearing load. A bearing is machine elements which support another moving machine
element (known as journal). It permits a relative motion between the contact surfaces of the members,
while carrying the load. In bearings, the relative motion between the two mating surfaces causes friction
and generates heat. Any substance placed between the two surfaces which reduces friction, wear and takes
away heat, is known as lubricant. In order to reduce frictional resistance and wear and in some cases to
carry away the heat generated, a layer of fluid (known as lubricant) may be provided. The lubricant used
to separate the journal and bearing is usually a mineral oil refined from petroleum, but vegetable oils,
silicon oils, greases etc. may be used.
5.8.1. A general classification of bearings
Based on the direction of load; On the basis of this criterion, bearings may be broadly classified into
two categories.
a) Radial bearings: those which carry external load perpendicular to the axis of rotation of the
shaft. Journal bearings and some types of ball and roller bearings belong to this category.
b) Thrust bearings: In these bearings, the load acts along the axis of rotation, e.g. hydrostatic
bearings and antifriction thrust bearings.
Based on the nature of contact; Bearings are also classified according to the nature of relative
motion between members.
a) Sliding contact bearings: Bearings with sliding friction between the members are called
sliding bearings, e.g. journal bearings and hydrostatic bearings.
b) Rolling contact bearings: Bearings with rolling contact friction between the members are
known as rolling contact bearings, e.g. ball, roller, and taper roller bearings. These bearings
have either point contact or line contact.
Page 49

5.8.2. Mechanical Requirements selection of bearings
The selection of a bearing for a particular application is based on several characteristics relating to
mechanical, environmental, and economic requirements.
The following considerations are of paramount importance in the selection of bearings:
Load: The rolling element bearing are superior to slider bearings because they can carry high
unidirectional and cyclic loads whereas the load carrying capacity of slider bearings depends on the speed
of journal.
Speed: Both sliding and rolling element bearings have a practical limit to the peripheral velocity, fixed by
different criteria. In sliding bearings, the speed limitation is on account of the rise in temperature of
lubricating oil caused by high speed shearing action. In rolling element bearings, the limit speed is a
function of the product of shaft diameter (mm) and speed in rpm. The limiting value of the shaft diameter
and speed factor is one million.
Misalignment: A slider bearing can tolerate misalignment better than what the rolling element bearing
can because the later has rigid structure and close tolerances.
Frictional loss: Rolling element bearings have low starting friction but journal bearings attain lower
coefficient of friction only when sufficient pressure is built up.
Lubrication: Rolling element bearings require only a small amount of lubricant. The ball bearings
operating at shaft diameter and speed value less than 0.3 million are pre-lubricated and can run for years.
Journal bearings, on the other hand, require a large amount of lubricant to maintain the oil film.
Space: Journal bearings occupy less space in radial direction whereas rolling element bearings require less
space in axial direction.
5.8.3. Bearing Material
A bearing, however carefully and properly designed, may fail either due to deflection, temperature
distortion, and surface roughness, contamination of oil or due to faulty selection of the bearing material.
Therefore, a proper selection of the bearing material is very important. Since the rolling elements and the
races are subjected to high local stresses of varying magnitude with each revolution of the bearing,
therefore the material of the rolling element (i.e. steel) should be of high quality. The balls are generally
made of high carbon chromium steel. The material of both the balls and races are heat treated to give extra
hardness and toughness.
5.8.4. Advantages of rolling contact bearings over sliding contact bearings
Low starting and running friction except at very high speeds.
Ability to withstand momentary shock loads.
Page 50

Accuracy of shaft alignment.
Low cost of maintenance, as no lubrication is required while in service.
Small overall dimensions.
Reliability of service.
Easy to mount and erect.
Cleanliness.
5.8.5. Life of a Bearing
The life of an individual ball (or roller) bearing may be defined as the number of revolutions (or hours at
some given constant speed) which the bearing runs before the first evidence of fatigue develops in the
material of one of the rings or any of the rolling elements. The rating life of a group of apparently
identical ball or roller bearings is defined as the number of revolutions (or hours at some given constant
speed) that 90 per cent of a group of bearings will complete or exceed before the first evidence of fatigue
develops (i.e. only 10 per cent of a group of bearings fail due to fatigue).
The term minimum life is also used to denote the rating life. It has been found that the life which 50
percent of a group of bearings will complete or exceed is approximately 5 times the life which 90 per cent
of the bearings will complete or exceed. In other words, we may say that the average life of a bearing is 5
times the rating life (or minimum life). It may be noted that the longest life of a single bearing is seldom
longer than the 4 times the average life and the maximum life of a single bearing is about 30 to 50 times
the minimum life.
5.8.6. Lubrication of bearings
The ball and roller bearings are lubricated for the following purposes:
To reduce friction and wear between the sliding parts of the bearing,
To prevent rusting or corrosion of the bearing surfaces,
To protect the bearing surfaces from water, dirt etc., and
To dissipate the heat.
The temperature should be kept below 90C and in no case a bearing should operate above 150C.
The static equivalent radial load ( ) for radial bearings under combined radial and axial or thrust loads is
given by the greater magnitude of those obtained by the following equations, i.e.
; And
The approximate rating (or service) life of ball bearings is based on the fundamental equation,
( )
Page 51

Where
The relationship between the life in revolutions (L) and the life working hours (
) is given by
Four our crusher we select a single row deep groove ball bearing from known shaft diameter (D=80mm)
which is equal to bore diameter (80mm) of bearing.
Using bore diameter (80mm) from a text book of machine design by Shigleys the following data is
selected.
Outside diameter =140mm
Bearing width = 26mm
Basic static (
) and dynamic ( )capacities of various types of radial ball bearings we select single
row deep groove ball bearing using diameter of shaft(bore diameter

capacities of static (
= 80mm) that has
basic
and dynamic( )
From shaft design we have radial load (
From belt design the speed (N) =246rpm
Now the approximate rating (or service) life of single row deep groove ball bearing is given as;
( )
(
From
The life working hours (
Depending on the bearing selected the housing for bearing will be also selected from the standard one.
Refer Appendix 2
5.9. Motor selection
A detailed understanding of type of motors, mounting, enclosures, duty helps in identifying appropriate
type of motor for the intended application. The criteria for motor selection includes: operating conditions,
driven equipment starting requirements (including the use of adjustable speed drives),
electrical
specifications, mounting requirements, enclosure and bearing parameters and accessory equipment needs.
Page 52

5.9.1. Operating conditions
Basic motor specifications begin with determining the motor nameplate HP and RPM. These are
determined by the process equipment supplier and are based upon a steady state equipment operation. For
the design of impact stone crusher motor specification is
From the previous data analyzed the maximum torque induced in the system is
The power required to drive this torque is given at 300rpmis given by
As a general since the motor is based on selection the horse power should be approximated to the standard
available motors in the market. We recommend selecting the motor with HP greater than 55.4HP.
Ambient temperature is often overlooked as a design criterion. Ambient temperatures below 30C can
require special bearing lubricant and material requirements. Conversely, ambient temperatures above 40
C may result in the allowable motor temperature rise to be lowered, which effectively de-rates the motor
output. The altitude at the site can also affect the motor selection when installation elevations exceed 1000
meters. The lower density of air at higher altitudes results in a decreased cooling media for the motor.
5.9.2. Driven equipment torque requirements
For shaft impact stone crusher we need a motor with high torque and low angular speed. That is why the
above specified motor type has been selected.
Service factor: The service factor (SF) of the motor is the level of overload the motor is capable of
maintaining above the nameplate power rating. A service factor of 1.0 or 1.15 is most common. A service
factor of 1.0 indicates the motor is specified and designed to not operate above the nameplate hp. Service
factors above 1.0 indicate the motor is suitable for continuous operation at the nameplate HP multiplied by
the SF. So the selected motor for continuous operation is with constant power and service factor is 1.
Motor classification for this project
Classification based on type: A.C current induction motor was selected for this horizontal shaft
impact stone crusher.
Classification based on mounting: -Horizontal mounting motor type which is general purpose motors
for conveyer, crusher and similar application such motors are in common use.
Based on motor duty: - It has been selected continuous duty motor with slot type that used to change
motor with different angular speed and easy maintenance.
Page 53

5.10. Design of Anvils
Anvils are the structures that help in crushing by further impacting with the material thrown by rotor
assembly. Also helps to adjust the size of the aggregates that would be crushed. These structures can be
made up of thick plates or beams fixed at one face such that we can change the orientation as well as
alignment so as to alter the distance between the rotor and the anvil. This mechanism also helps in
changing the angle at which the material impacts on the anvil so as to get the required size and
shape of the fragmented particles. A number of such anvils are used to get the fragmentation at
different levels and angles.
Since it is subjected to the impacting force of the particle the material that would be selected for the
design of the anvils have to resist this impacting force. For design of a anvils Manganese steel is selected
due to its high impact strength and resistance to abrasion once in its work-hardened state. The detail
mechanical properties of manganese steel were explained in the above section, design of hammer.
Mechanical properties of mild steel C40/SE40
Tensile Strength=550Mpa
Yield Strength=320Mpa
Shearing strength = 60Mpa
Factor of safety=2
Standard thickness =12mm
In the anvils design there are four subcomponents have to be designed carefully:A) Hammer
B) Hammer holder plate
C) Anvils holder plate
D) Pin
a) Design of hammer
The hammer is subjected to the impact force generated from the rotor assembly due to centrifugal force
direct bending stress may be important criteria to be considered. Due to this reason since the impact force
exerted on rotating hammer and stationary hammer is the same the geometry with rotating hammer will be
used for the stationary hammer, i.e. thickness of 45mm.
Page 54

b) Design of hammer holder plate
Hammer holder plate is used for the purpose of holding hammer assembled on it by bolting mechanism.
Since it is subjected to distributed impact force mild steel C40/SE40 at standard thickness of 12mm
selected to with stand the impact force and checked for its strength.
There are two anvils primary and secondary anvils and on each one of them they do have two plates.
Force exerted by incoming particle
. Where m is the of incoming particle which is equal the
tonnage per hour 50kg/s and with respect to the radius of the rotor and angular velocity of the rotor.
Using the data from the previous section
(
From the loading for the impact, let assume impact factor of 3.
Area of the plate is
Assuming that the force is distributed over the plate the maximum bending moment occurred on the plate
is calculated as
(
The bending stress induced due to this bending moment is given by

(
We can conclude that the plate is free from bending due to the applied impact force on it, since the
induced bending stress is less than the allowable stress of the material.
c) Anvils holder plate
It is the plate on which the hammer holder plate will be mounted by welding mechanism to be pinned at
its end with the housing or casing.
Assuming that the force is distributed over the plate the maximum bending moment occurred on the plate
is calculated as
Page 55
Considering the moment at point A is zero
Taking the summation of force along y axis and solving for the reaction force at point A
Now calculating for the induced stress due to maximum bending moment
(
The bending stress induced due to this bending moment is given by

(
We can conclude that the plate is free from bending due to the applied impact force on it, since the
induced bending stress is less than the allowable stress of the material.
d) Pin design
For the anvils assembly we have two pin: to attach with housing and for the size reducer shaft/ stud.
Considering the reaction force at the joints the pin is designed by considering the shearing strength.
For double shearing the diameter and the pitch is given by
And
and the thickness is

(
Check for shearing strength in the pin using the maximum force which will cause failure
)
Page 56
The above result shows that each induced stress is less than the allowable stress of the material, which will
tell us that the pin is safe from tearing, shearing, and crushing.
5.11. Design of size reducer shaft
Size reducer shaft is the component of anvils which used to adjust the size at which aggregate crushed
during crushing. It will operates by translating the anvils assembly to back and forth motion and contracts
the spring which helps to return the anvils back when un expected force come into crushing from the input
product in order to prevent the rotor from stacking with input product properties. We used pin assembly at
the back side of the anvils to connect with the anvils and it is directly subjected to buckling stress. The
design of this component will be in terms of strength.
Material selection and stress analysis
As we have discusses in the previous section, shaft design, the same material is also used here for this
component.
Shaft material is AISI 9255 steel
Elastic Modulus
200Gpa
Poissons Ratio
0.29N/A
Shear Modulus
77Gpa
Density
7900kg/m^3
Tensile Strength
932.9Mpa
Yield Strength
579.2Mpa
Factor of safety
The critical load on the shaft will be the force transferred from the anvil due to impact. Considering the
shaft for the buckling
From the overall dimension of the shaft the length of the shaft will be 400mm
The critical load is given by
The critical stress is given by
Page 57
The diameter of the shaft will be approximating to the standard, Since the shaft is adjustable through the
bolt and nut mechanism the translational motion of the shaft have to be external threaded which will be
related to the maximum deflection of the spring mounted on it to resist the impact force through storing as
an energy in the spring. The diameter will be used as a core diameter of the thread and the dimension
related to this value will be selected from the standard table appendix 3 Select M30.
5.12. Design of spring
A spring is a device that changes its shape in response to an external force, returning to its original shape
when the force is removed. The energy expended in deforming the spring is stored in it and can be
recovered when the spring returns to its original shape. Generally, the amount of the shape change is
directly related to the amount of force exerted. If too large a force is applied, however, the spring will
permanently
deform
and
never
return
to
its
original
shape.
A compression spring is an open-coil helical spring that offers resistance to a compressive force applied
axially by the anvils. Compression Springs are the most common metal spring configuration and are in
fact one of the most efficient energy storage devices available. Other than the common cylindrical shape,
many shapes are utilized, including conical, barrel and hourglass. When anvils transfer a load from
impact, it pushes back against the load in order to eliminate the stacking of the motor with the adjustable
stationary hammer or anvils and tries to get back to its original length.
Input date for spring design
Weight =34508.6N
Free length =400mm
Size reducer shaft diameter =25mm
Maximum deflection of 150mm
Page 58

Material selection for spring
Carbon steel
Allowable shear stress =364Mpa (average condition time appendix 13)
E=210Gpa
G=80Gpa
Assume spring index, C=5
Number of spring
a) Dimension of spring
Solid length of the spring would be
The assumed maximum deflection is
and free length is
From the stress analysis of helical compression spring the maximum induced stress due to the axial load
applied and curvature of wire is given by equation
The allowable shear stress of carbon steel at average condition from the selected material is
Wahls stress factor can be obtained by
The wire diameter of the spring is approximated to be

The mean diameter of the spring would be calculated from spring index as given below
Page 59
Number of coils,
is given
Pitch of the spring is given by
Spring rate is given by
The suitable end connection of the helical compression spring selected for this design is squared and
ground ends. Due to the end connection there are modification factors needs to be considered. These
factors could modify the values of the number of coil, free length and solid length. Given by
Total number of turn
Solid length
Free length
b) Check Buckling Of Compression Spring

It have been found that when the free length of the spring
is more than four times the mean spring
diameter (D), then the spring behaves like a column and may fail by buckling at a comparatively low
load. The critical axial load
Where:
that causes buckling may be calculated by: [
].
Buckling factor
[
]: k spring rate or stiffness of the spring (
) and
free length of the spring.
5.13. Design of grinding screen

Screening is a process of separating into groups of different products of various sizes. Each group consists
of products of approximately same size. The mass, which remains on a screen, is called the oversize of the
screen and the material, which passes through the screen, is called the undersize. The screens in between
the primary and the secondary crusher help in separating the oversize. The oversize goes to the secondary
crusher while the undersize is discharged through a chute on to the same conveyor belt, which receives the
discharge from the secondary crusher. This saves considerable power in the second crushing stage and
Page 60

also increases the capacity of the secondary crusher, as it eliminates possible choking of material in the
crusher, particularly during wet weather or wet material.
5.13.1. Classification of grinding screening
Screening is generally classified into two types:(i) Course screening, which is achieved through Grizzlies, Vibratory Screens, Revolving Screens or
Shaking Screens and
(ii) Fine screening which is achieved through vibrating screens, Shaking Screens.
Brief description of various screening technologies is given below:a) Grizzlies type Screens
The Grizzlies are normally used to remove "undersize" before primary or secondary crushing. Grizzlies
are of three types, Stationary, Cantilever and Mechanically vibrated types.
Stationary Grizzlies: Course screening of dry type material is done with the help of stationary grizzlies.
It is inclined (plus or minus 300) so that the feed slides down appreciably. The grizzly is made selfclearing by having bars placed in such a way that there is maximum width at the top and minimum width
at the bottom.
Cantilever Grizzlies: The grizzly is fixed at one end and the discharge end overhangs and is free to
vibrate. The vibration of the bars results from impact of the material. This type of grizzly is more effective
than the stationary type due to its design. (There are no cross rod which are found in the stationary type).
This type of grizzly can handle larger tonnages, it is simple to use and easy to repair and operate.
Mechanically Vibrated Grizzlies: These grizzlies are simply bars mounted on the eccentrics. This is the
most common type of grizzly used.
b) Vibrating Screen
Vibrating Screens save space and weight, and operate on little power because the screening surface may
be actuated by vibrating, gyrating or pulsating movement of small amplitude, but at frequencies that
normally exceed 3000 cycles per minute. Combination of frequency of vibration (speed) and amplitude
(throw), affects performance of any vibrating screen. A correct combination of slope and direction of
mechanism of rotation is vital for inclined screens. The larger the opening the greater the amplitude
needed for a screen.
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c) Rotary Screen
Rotary Screens are cylindrical shape perforated steel cylinders, which keeps rotating during screening
operation. The crushed stones from the crusher are fed at one end and travels to the other end and during
process material of various sizes gets screened as per the diameter of the perforated screen.
These screens are fitted below such that they help in segregating the output material according to their
sizes and channel the outflow of the required size particles. Once the particles are on the Screen there are
two processes that occur on it;
Stratification: This is the process whereby the large-sized particles rise to the top of the vibrating material
bed due to the vibrating motion effect, while the smaller particles sift through the gaps and go to the
bottom of the bed.
Interrelated factors that affect stratification are:
1. Material travel flow: a function of the material stratification, bed thickness, stroke characteristics, and
screen slope
2. Stroke characteristics: amplitude, direction, rotation, type of motion, and frequency
3. Surface particle moisture: high surface moisture content makes stratification difficult
The vibrating motion is generally produced by the vibrating mechanism based on eccentric masses with
amplitude of1.5 to 5mm and operation in range of 800 to 900 rpm.
It should have proper amplitude and frequency so that the material while travelling on the screen neither
falls on the same opening nor jump over many subsequent openings. So if we have larger openings we
require higher amplitude and lower speed. But in case of smaller openings were quire lower amplitude and
higher speed.
The screens can be horizontal as well as inclined. In horizontal screen the motion/vibration should be
capable of conveying the material without the need of gravity. So a straight line motion /vibration at an
angle of45 to the horizontal can produce lifting component for the stratification and conveying. Low
screening efficiency leads to over load of the closed crushing circuit as well as it may lead to products that
are non-compliment with specification.
It was also studied that the efficiency of screen depends on the feed on the screen. As in the earlier lower
feed the efficiency increases with increase in feed but later on the efficiency decreases with further
increase in the feed rate. The mesh openings should always be slightly larger than the specified separation
size.
Page 62

For our assumed input feed for the screen, feed rate =180 TPH
It is desired to select a screen for the following application:
Data: a) Feed = 180tons/h
b) Material feature
Solid density=2.7 t/m3
Max feed size =100 mm
Moisture content =3%
Particle shape= flaky; Screening process = dry
Desired products = larger than 40 mm (that are circulated back to crusher input); and
between 40 mm and 10 mm.
c) Dry screening process
d) No room limitations
e) Desired products: larger than 40 mm, between 10 and 40 mm, and smaller than 10 mm.
5.13.2. Screen selection
75% of the passing material in collected in the first deck (level) of the screen. Passing material percentage
through the second deck (10 mm) is related to its loading and is
Since the passing percentage for the deck is very high we use multi-slope screen. The flaky material shape
leads to the choice of square opening screen. We assume the use of steel screening mesh.
Dimensioning
Feed: 180TPH
First deck: separation of 40mm
At the first deck particle with size greater than 40mm should be retained and the rest should be passed to
the conveyor.
To obtain 40mm separation the square opening screen must be 48mm and with an opening of 73%.
(
A= 53 (chart B for 40 mm separation)
B= 1.35 (chart C for 25 % oversize)

Page 63

C= 1.1 (chart D for 45 % half size)
L= 1 (square opening)
D= 1 (first deck)
I= 0.9 (Flaky)
E= 1 (dry screening)
J= 1 (assumed 90% efficiency)
F= 1 (2.7 t/m3)
K= 1.3 (Square opening screen)

L= 1 (3% moisture)
So,
5.14. Design of Housing (Casing)
The crusher case can be made up of welded steel construction and built in three or more sections. The
lower half is made up of one piece and upper half is made up of two sections. The feed intake
section is in the upper half and is bolted to the lower half resulting in a lasting dust type
connection between the feed and crusher intake.
The rest of the top section is hinged for access to interior of the crusher for changing hammers,
hammer pins and rotor plates. All the mating surfaces are built-up for an accurate, dust tight fit. Single
latch door is provided for easy maintenance and cleaning and a Gasket door is provided for dust
tight operation. The casing of the crusher does not experiences and larger forces but still they should be
able to bear abrasive forces acting on it. The impact bars are attached to the casing through a mechanism
which may help in changing the angle of impact on the bar, by moving or tilting the bar.
5.14.1. Material selection
AISI 1018 mild/low carbon steel has excellent weld ability and produces a uniform and harder case and it
is considered as the best steel for carburized parts. AISI 1018 mild/low carbon steel offers a good balance
of toughness, strength and ductility. Provided with higher mechanical properties, AISI 1018 hot rolled
steel also includes improved machining characteristics.
Mechanical Properties
Tensile strength, ultimate=440Mpa
Tensile strength, yield=370Mpa
Modulus of elasticity=205Gpa
Bulk modulus
=140Gpa
Poisons ratio=0.290
Density=7.87g/cc
Page 64

The dimension of the casing is given as from the geometry
Total weight of parts assembled on the machine will be (
The housing or casing of the machine has rectangular geometry made from plate. In order to improve the
stress along from the weight of different masses of the machine component the external outside of all
casing is supported by ribs. Which enables from bending the casing, since the rigidity of the casing is
more important to resist the vibration occurred by the dynamic motion occurred during operation by
adding ribs to the external side of the casing the ability resist the bending and the vibration will be
improved.
The housing or casing id so designed in order to resist stresses due to the weight of components in terms
of strength. By considering the compressive strength of the material selected for the housing from the
standard one.
The allowable maximum stress for the design is
The stress due to the weight produced in the casing is calculated as
Generally the stress distribution is very small compared to the material property, but as we tried to explain
in the above section the rigidity of the casing is increased by adding ribs to the external side of the casing
which will be done by welding to the main housing.
5.14.2. Bolt Selection for the assembling of housing
Important Terms Used in bolt
The following terms used in screw threads:
Major diameter. It is the largest diameter of an external or internal screw thread. The screw is
specified by this diameter. It is also known as outside or nominal diameter.
Minor diameter. It is the smallest diameter of an external or internal screw thread. It is also known
as core or root diameter.
Pitch diameter. It is the diameter of an imaginary cylinder, on a cylindrical screw thread, the
surface of which would pass through the thread at such points as to make equal the width of the
thread and the width of the spaces between the threads
Pitch: It is the distance from a point on one thread to the corresponding point on the next. This is
measured in an axial direction between corresponding points in the same axial plane.
Page 65
Lead: It is the distance between two corresponding points on the same helix. It may also be defined
as the distance which a screw thread advances axially in one rotation of the nut. Lead is equal to
the pitch in case of single start threads; it is twice the pitch in double start, thrice the pitch in triple
start and so on.
Crest: It is the top surface of the thread.
Root: It is the bottom surface created by the two adjacent flanks of the thread.
Depth of thread: It is the perpendicular distance between the crest and root.
Flank: It is the surface joining the crest and root.
Angle of thread: It is the angle included by the flanks of the thread.
Slope: It is half the pitch of the thread.
5.14.2. Common Types of bolt

1) Through bolts. It is a cylindrical bar with threads for the nut at one end and head at the other end. The
cylindrical part of the bolt is known as shank. It is passed through drilled holes in the two parts to be
fastened together and clamped them securely to each other as the nut is screwed on to the threaded end.
The through bolts according to their usage may be known as machine bolts, carriage bolts, automobile
bolts, eye bolts etc.
2. Tap bolts. A tap bolt or screw differs from a bolt. It is screwed into a tapped hole of one of the parts to
be fastened without the nut.
3. Studs. A stud is a round bar threaded at both ends. One end of the stud is screwed into a tapped hole of
the parts to be fastened, while the other end receives a nut on it. Studs are chiefly used instead of tap bolts
for securing various kinds of covers e.g. covers of engine and pump cylinders, valves, chests etc.
4. Cap screws. The cap screws are similar to tap bolts except that they are of small size and a variety of
shapes of heads are available.
From the previous data the centrifugal force generated from the rotor which will be transferred to the
machine body where considered as an internal pressure applied on the bolts or fastening mechanism.
5.14.3. Material selection for bolt and nut
This force can be related to the tensile stress by the formula given as below
Page 66

So from the standard coarse series hexagonal bolt type with
core diameter bolt will be
selected, M33.
,
and
5.14.4. Stresses in bolt due to Static Loading

The following stresses in bolt due to static loading are important from the subject point of view:
1. Internal stresses due to screwing up forces,
2. Stresses due to external forces, and
3. Stress due to combination of stresses at (1) and (2).
Initial Stresses due to Screwing up Forces
a) Tensile stress due to stretching of bolt.
Since none of the above mentioned stresses are accurately determined, therefore bolts are designed on the
basis of direct tensile stress with a large factor of safety in order to account for the indeterminate stresses.
The initial tension in a bolt, based on experiments, may be found by the relation
The above relation is used for making a joint fluid tight like steam engine cylinder cover joints etc. When
the joint is not required as tight as fluid-tight joint, then the initial tension in a bolt may be reduced to half
of the above value. In such cases
The small diameter bolts may fail during tightening, therefore bolts of smaller diameter (less than M 16 or
M 18) are not permitted in making fluid tight joints.
If the bolt is not initially stressed, then the maximum safe axial load which may be applied to it, is given
by
P= Permissible stress Cross-sectional area at bottom of the thread (i.e. Stress area)
So the maximum safe load that applied to bolt is given as:
P=permissible stress x stress area
P=56Mpa x 561mm2 =31416N
b) Shear stress across the threads.
The average threads shearing stress for the screw ( ) is obtained by using the relation:
Page 67
Where b=Width of the thread section at the root=Pitch

(
The average thread shearing stress for the nut is
Where d= Major diameter

(
c) Compression or crushing stress on threads

The compression or crushing stress between the threads (
(
) may be obtained by using the relation:
Where d= Major diameter

=Minor diameter and
n =Number of threads in engagement
(
5.16 Retaining rings (Snap rings)

Shoulders is an economical way of positioning parts on a shaft. But it usually requires shafts of very
large diameter and it is a costly procedure. With retaining rings also called as snap rings or Circlips,
designers can allow for smaller shaft diameter and reduce machining to cutting a narrow circular groove.
Retaining rings work only when a small amount of axial ply is permissible. They provide a removable
shoulder to locate, retain or lock accurately components on shafts or in bores and housings. So base on
designed shaft diameter snap rings has been chosen.
Material used: Retaining rings are usually made of spring steel and remain seated there in a deformed
position.
Application: Retaining rings can be used to replace cotter pin and washer set screws and collar or nut and
shoulder shafts. Thus they effectively lower the costs of fastening and assembly.
Disadvantages: snap rings require grooves for seating, which are stress raisers. Hence snap rings should
be avoided in areas of high stress, for hence, in the central section of a simple supported shaft carrying a
heavy load in bending.
Page 68

5.16 Design of mass unbalance
Analysis of vibration system involves: Physical modeling
Mathematical modeling
Analysis
Validation of the results with measured values and
Refinement if necessary
The mechanical model has to simplify so that it could be easily be solved but sufficiently sophisticated to
the real system, physically, all elements of mechanical system are of continues type and to make the
analysis simple and not to deal with non-liner characteristic of all components, we need to:
Take simplified assumptions and identify the basic parts which have relevance to the problem.
Model by lumped or discredited equivalent, which are the mass, spring and damper.
5.16.1 Forced vibration of a single degree of freedom linear system
Forced vibration the energy source will not be removed and work is continuously being done on the
system while vibration occurs like rotating components constantly excited by harmonic force of a driving
motor.
General equation of forced vibration using
( )
This is non-homogenous order differential equation then the response using the superposition homogenous
response,
( ) a particular response,
( ) i.e.
Total response = response of initial condition + response of external forces

5.16.2 Rotating unbalanced masses
This kind of excitation is an example of forced vibration is a result of small extra irregularities in the
distribution of rotating mass.
The equation of the motion governing the translational motion for the case of no damping (c = 0) is given
by:
( )
( )
Note that the excitation F (t) could have a sin or cosine form. Here we have taken the cosine. Dividing the
above equation by the mass m and rearranging, we have;
( )
( )
Where
Page 69

This is linear no-homogenous ordinary deferential equation and total response of the system will have the
homogenous (complimentary) and the particular part using the methods of the undetermined coefficient
( ) will be given by:
the particular solution,

()
Where
= is the amplitude of the forced vibration.

()
The total response
( ) is the sum of the homogenous solution (transient response),
particular solution (steady state response),

()
()
( );
()
()
))
( ) term decays exponentially approaches to zero; as a result, the ( )
For the larger value time t the

approaches
( ) and the
( ) and the response will be:
()
The first derivative i.e., the velocity response of the system will also be given by;
()
And excitation force ( )
)
(
Total static load with the mass of the machine supported by the helical spring is 251kg assuming the
spring ends are always in contact with the plates. In order to reduce the vibrational energy of the machine
by selecting appropriate spring which will be absorb vibrational energy from the system. [18]
Figure 5.12: Free body rotating unbalance
The natural frequency of the system
is given by;
Page 70
And the frequency of the motor from its property
The above value tell us that the natural frequency is greater the frequency of the motor which will make
the design safe from vibration.
Page 71
6. DESIGN FOR MANUFACTURING PROCESS

The fundamental idea of manufacturing or production is to create, (or produce), something that has a
useful form. This form is most likely predetermined and calculated, with a certain physical geometry.
Usually this geometry has certain tolerances that it must meet in order to be considered acceptable. A
tolerance outlines the geometric accuracy that must be achieved in the manufacturing process. The
"tightness" of the tolerances, or in other words the allowed variance between the manufactured product
and the ideal product, is a function of the particular application of the product.
Goals and Core Principles for All Processes
Meeting performance requirements (i.e. tolerances, strength, weight, etc.)
Meeting cost of production requirements
Ability to reproduce constant quality during mass production
Large manufactured components should have uniform material properties throughout the component
6.1. Manufacturing process by casting
Casting manufacturing process will be carried for the following parts:
A) Anvils hammer
B) Rotor plate
C) Flywheel
D) Pulley
The manufacturing of hammer involves two processes, namely machining for the rotating hammer and
casting for the stationary hammer or anvils assembly.
Casting is a manufacturing process by which a liquid material is usually poured into a mold, which
contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also
known as a casting, which is ejected or broken out of the mold to complete the process. Sand casting is the
most widely used metal casting process in manufacturing and hammer for the anvils will be manufactured
by casting. Anvils hammer, rotor plate and pulley involve casting by sand method. [14]
Table 6.1: weight of parts manufacture by casting
No. Part name
Quantity
Weight/item
Total weight
Anvils hammer
28
954.58 grams
26.73Kg
Rotor plate
77175.80 grams
385.88Kg
Flywheel
21992.84 grams
21.99Kg
Pulley
2788.25 grams
2.788Kg
Page 72

5
Small pulley
451.05 grams
0.451Kg
Rotating hammer
86371.63 grams
345.48Kg
Flywheel: - The flywheel begins manufacturing by die-casting. This involves the hot chamber process
which casts the flywheel use large amounts of pressure and temperature using a single-cavity dies. The die
contains two pieces, the first half of the die contains the cavity for the main body, and this forms the
wheel. Die-casting is a century old process of injecting molten metal in to a steel die under high pressure.
The second half of the die contains protrusions creating the arms and holes for it to connect to the shaft.
Creating the holes during the casting process eliminates a drilling process and save valuable time money.
The two halves of the die connect at the top of the flywheel surface. Once this process is complete the
piece then needs for a better fit and tighter tolerances.
6.1.1. Casting Operation
The sand casting operation involves: the pouring of the molten metal into the sand mold
the solidification of the casting within the mold
the removal of the casting and
the casting operation is covered in detail on the metal casting operation page
Manufacturing with sand casting allows the creation of castings with complex geometry. Sand casting
manufacture, however, only imparts a fair amount of dimensional accuracy to the cast part.
After the sand casting is removed from the sand mold it is shaken out, all the sand is otherwise removed
from the hammer, and the gating system is cut off the part. The part may then undergo further
manufacturing processes such as heat treatment and machining for drill. Inspection is always carried out
on the finished part to evaluate the effectiveness and satisfaction of its manufacture. [14], [10]
The molten and core mass needed to manufacture the rotor plates is
Required bouncy for each rotor plate

Weights are determined as the volume of the core multiplied by the respective densities of the core
material (typically sand) and the metal being cast. The density of a sand core is approximately 1.6 g/cm 3.
The volume of the parts will be calculated as,
or using solidwork software.
Page 73

6.2. Manufacturing by machining
In order to manufacture the following components of the machine machining operation will be common
method.
A) Rotating shaft
B) Size reducer shaft
C) Rotating hammer
D) Casing or body
E) Grinding screen
In machining, a manufactured part is created to its desired geometric dimensions by the removal of excess
material from a work piece, via a force exerted through a certain material removal tool. Qualities of a
desirable manufacturing material for this purpose would be:
Lower Shear Strength (to make cutting easier)
Shock Resistant (to withstand impact loading)
Material must not have a tendency to stick to the cutting tool
Material removed should separate from the work easily and completely
A material's relative ability to be machined is called machinability. Machinability varies among metals;
hardened metals present a particular problem, due to very high shear strength. Often, they are machined as
close to their final shape as possible before being hardened. That way, the hardened material only has to
undergo minimal finishing operations. This type of manufacturing process has many advantages.
Machining accuracy allows it to produce surface finish and smoothness that cannot be achieved any other
way.[10] The following operation will be carried out:Cutting parameters
In turning, the speed and motion of the cutting tool is specified through several parameters. These
parameters are selected for each operation based upon the work piece material, tool material, tool size, and
more.[8]
Cutting feed - The distance that the cutting tool or work piece advances during one revolution of
the spindle, measured in inches per revolution (IPR).
In some operations the tool feeds into the work piece and in others the work piece feeds into the
tool. For a multi-point tool, the cutting feed is also equal to the feed per tooth, measured in inches per
tooth (IPT), and multiplied by the number of teeth on the cutting tool.
Cutting speed- The speed of the work piece surface relative to the edge of the cutting tool during a cut,
measured in surface feet per minute (SFM).
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Spindle speed- The rotational speed of the spindle and the work piece in revolutions per minute (RPM).
The spindle speed is equal to the cutting speed divided by the circumference of the work piece where the
cut is being made. In order to maintain a constant cutting speed, the spindle speed must vary based on the
diameter of the cut. If the spindle speed is held constant, then the cutting speed will vary.
Feed rate - The speed of the cutting tool's movement relative to the work piece as the tool makes a
cut. The feed rate is measured in inches per minute (IPM) and is the product of the cutting feed (IPR) and
the spindle speed (RPM).
Axial depth of cut- The depth of the tool along the axis of the work piece as it makes a cut, as in a facing
operation. A large axial depth of cut will require a low feed rate, or else it will result in a high load on the
tool and reduce the tool life. Therefore, a feature is typically machined in several passes as the tool moves
to the specified axial depth of cut for each pass.
6.2.1. Rotating Shafts
For simplicity of manufacturing process large diameter of the selected material is machined on lathe by
different process of machining. In order to gets the desired diameter of the shaft using turning process. In
turning, a cutting tool with a single cutting edge is used to remove material from a rotating work piece to
generate a cylindrical shape. The speed motion in turning is provided by the rotating work part, and the
feed motion is achieved by the cutting tool moving slowly in a direction parallel to the axis of rotation of
the work piece.
a. Bar cutting
Bar cutting is the first step to be carried out on the shaft on reducing the shaft first stage with power hack
saw. It is necessary to determine the machining time will be taken during bar cutting. The blank diameter
of the part is 80mm with length of 1500mm and the machining time
(
A=circumscribing cross sectional area (mm2)

As=specific cross sectional area (mm2/min)
b. Facing operation
The blank dimension of the part is diameter of 80mm and 1500mm in length and the main dimension is
1493mm. The part needs 7mm to be machined with facing to bring to the main dimension the light lathe
machine. The mean cutting speed for 2mm depth of cut from appendix table 21 30000mm/min with feed
of 0.3mm/rev and then spindle speed is
Where N=rotational speed
Page 75

V=cutting speed
Do=original diameter of the part,
The feed in turning is generally expressed in mm/rev
The time to machine is given by
c. Turning machining time

The turning operation reduces the diameter of the work from its original diameter
Do to Df a final diameter Df, as determined by the depth of cut d:
The metal to be removed in turning operation is 5mm and 2mm for one passes of rough cut and 0.5mm for
fine cut. The mean cutting speed for 2mm depth of cut for carbon steel from appendix table 21
30000mm/min with feed of 0.3mm/rev
Again for the fly wheel and pulley diameter

For pulley diameter, d = 65mm
Page 76

For flywheel diameter d = 75mm
6.2.2. Size reducer shaft

a. Bar cutting
The blank diameter of the part is 30mm with length of 410mm and the machining time
(
A=circumscribing cross sectional area (mm2)

b. Facing operation
The blank dimension of the part is diameter of 30mm and 410mm in length and the main dimension is
400mm. The part needs 10mm to be machined with facing to bring to the main dimension the light lathe
machine. The mean cutting speed for 2mm depth of cut from appendix table 21 30000mm/min with feed
of 0.3mm/rev and then spindle speed is
Where N=rotational speed

V=cutting speed
Do=original diameter of the part
c. Turning machining time

The turning operation reduces the diameter of the work from its original diameter
Page 77

Do to Df a final diameter Df, as determined by the depth of cut d:
The metal to be removed in turning operation is 5mm and 2mm for one passes of rough cut and 0.5mm for
fine cut. The mean cutting speed for 2mm depth of cut for carbon steel from appendix table 21
30000mm/min with feed of 0.3mm/rev
6.2.3. Rotating hammer

a. Bar cutting
The blank area of the part is 45mmx1000mmx250mm and the machining time
(
Where A=circumscribing cross sectional area (mm2)

And finally groove will be machined at a specified radius
6.2.4. Body
The casing or housing is manufactured using machining and welding, by classifying them into three main
parts, namely: The bottom part which include the manufacturing of each side separately and assemble them by the
recommended or selected bolt type.
The upper back side, on which the assembly of the anvils is mounted on it
The upper front side, which enables the product to feed in the machine
The supporting ribs are first prepared by cutting to the specified dimension they will be welded as
described on the drawing.
Page 78

6.2.5. Grinding screen
6.3. The Manufacturing Process of spring
Springs are manufacturing by hot or cold working process depends up on the size of the material the
spring index and properties desired. [22]
The following process would be involved in manufacturing spring: The wire is pushed forward over a support block toward a grooved head that deflects the wire, forcing
it to bend. The head and support block can be moved relative to each other in as many as five
directions to control the diameter and pitch of the spring that is being formed.
Thicker wire or bar stock can be coiled into springs if the metal is heated to make it flexible. Using
standard industrial coiling machines, steel bar up to 30mm in diameter coiled. The steel is coiled
around a mandrel while red hot. Then it is immediately removed from the coiling machine and
plunged into oil to cool it quickly and harden it. At this stage, the steel is too brittle to function as a
spring, and it must subsequently be tempered.
After the steel has been coiled hot, the process has created stress within the material. To relieve this
stress and allow the steel to maintain its characteristic resilience, the spring must be tempered by heat
treating it. The spring is heated in an oven, held at the appropriate temperature (500F (260C)) for a
predetermined time, and then allowed to cool slowly.
The ends are ground at this stage of the manufacturing process. The spring is mounted in a jig to
ensure the correct orientation during grinding, and it is held against a rotating abrasive wheel until the
desired degree of flatness is obtained first by coarse wheels and then by finer wheels. An appropriate
fluid (water or an oil-based substance) may be used to cool the spring, lubricate the grinding wheel,
and carry away particles during the grinding.
To permanently fix the desired length and pitch of the spring, it is fully compressed so that all the coils
touch each other.
To prevent corrosion, the entire surface of the spring is protected by painting it, dipping it in liquid
rubber.
6.4. Manufacturing by forging
To manufacture pin, upsetting type of forging process is selected. Heading or upset forging is a process by
which stock, (typically cylindrical), is upset at its end in order to increase the cross section of the material
in this area. The process is hot, but often a cold working operation will be held on, which will take
advantage of the strengthening of the material in the region worked. Heading is performed horizontally, as
shown in the diagrams. The impression in the head may be forged in the punch, the die, or both.[12]
Page 79
7. MANUAL OF THE MACHINE

7.1 Maintenance
Maintenance is a process of repairing and maintaining braked or failed parts. During maintenance time
before starting any maintenance procedures first we should have to be check whether the machine is stop
or not and beside that check any danger. And also before starting any operation we should have to check
the bolt, nut and every part of the machine is on its exact or appropriate position. In this design we only
focused maintenance of parts those have special use in the function of the machine.
7.1.1 Rotor assembly maintenance:
Includes maintenance of the following parts; rotor assemblies are contained part like hammer, rotating
shaft and rotor plate.
A) Hammer maintenance
Hammer crusher is applicable for various hard and fragile materials, such as limestone, coal, salt, gypsum,
alum, brick and tile, etc. therefore during the operation the hammer may fail. Then to resolve this problem
the entire hammer should mount on its exact position but when the hammer is fail follow the maintenance
step mentioned below. In this machine when the hammer is fails ones it is no more in service after that fail
the part is throw away.
Open housing and removing the failed part
Replace with the new hammers
B) Rotating shaft maintenance
This Shaft is one component rotor assembly which transfers the torque and cares all loads. So this
component may fail by factor of bending or twisted. Therefore to maintain when it fails as we follow
maintenance procedure mentioned below
Firs open machine house and bearing house.
Removing bearing from shaft and bearing house, rotor plate and hammer assembly from shaft and
replaced by new shaft
C) Rotor plate maintenance
This rotor plate is the part which used to support the hammer to resist the load or pressure happened on it
from stone so to maintain when this part fail.
Firs open machine house and bearing house.
Removing bearing from shaft and bearing house, disassemble hammer from rotor plate and finally
remove rotor plate from shaft and replace it by new rotor plate.
Page 80

7.1.2 Anvils assembly maintenance
Anvils assembly is contained part like size reducer shaft, stationery hammer, spring.
A) Size reducer shaft maintenance
Size reducer shaft is parts which use to adjust the size of product aggregate output. These parts are the one
which subjected to buckling and compressive stress so during operation it may fail by deforming and
buckling. Before this part fail the one who maintain the machine should have to be check the bolt on the
head of the shaft assembled strictly and when the part completely fail repair by following the following
steps;
First remove the nut from its head and spring
Open house of machine on back side.
Separate shaft and stationery hammer which connected by pin
And finally replace by new one.
B) Stationary hammer maintenance
This hammer is used to crush the particles which through from rotating hammer to its required size. So
this part may fail and make movement from its position this movement happen when the bolt and the nut
hold the hammer on its position is not adjusted strictly. The one who maintain the machine should have to
be careful. And when this hammer fails by removing bolt remove the part from assembly of anvils and
replace with new hammer.
C) Spring maintenance
Spring is the part which used to store the unexpected impact force from the rotor in order to eliminate the
stacking of the rotor assembly. During its working life it affected by compressive and tensile load and it
may fail, therefore solving this fail by mounting on its exact position to be mounted and repair by new
spring when it damage all in all.
7.1.3 Bearing
Bearing is one of the machine part which used to make rotation of the shaft, pulley and flywheel easy.
This component is not exposed to fail easily because it has long life time. This part is the part which must
be getting all time appropriate lubrication because to gate the maximum efficiency. But if the fail is
happen the maintenance process used is as mentioned below.
Firs open house of machine and bearing.
Removing the failed part bearing from shaft and replaced by new bearing.
Page 81

7.2 Assembly process
Assemble is Process of building the machine from all parts and components of the machine. This machine
assembled by classifying the machine into three big assemblies process.
Rotor assemble
Mount rotor plates on shaft and lock them with locking key, and adjusting their slots alignment
for hammer insertion.
Insert longitudinal the hammer on the rotor plate slots mating with grooves.
Assemble bearing in the bearing house.
Insert on two sides of the shaft bearing assembly
Anvils assembly
Assemble stationery hammers on anvils holder by using Allen head bolts.
Insert pin at the back of the anvils holder.
Assembly with pin, size reducer shaft, spring, nut, and upper back side of the housing together.
Body assemble
Using the selected bolt on parts of the body, right side, left side, front side, and back side.
Mount bearing house on the both left and right side of housing.
Mount the rotor assembly by the bolt on the house.
Assemble the front side (feeding side) of the housing on the bottom assembly.
Assemble the upper right side and left side housing.
Mount the primer and seconder anvils assembly with upper back side housing and finalize the top
housing cover.
Mount the flywheel by the left side of the house on the shaft and the pulley by the right side of the
housing on the shaft.
Finally assembly the motor and the pulley by using belt.
7.3 Disassembly process
Disassemble is Process of reversing the process used during assemble or mounting the machine.
Page 82
8. COST ESTIMATION
8.1. Cost estimation methodology
The main elements of cost are material, labour, energy, tooling and overhead costs. These are primarily
driven by product and process parameters. The metal and part weight forms the basis of material cost.
Process planning data in terms of process/equipment used and hours required for each activity forms the
basis of labour cost. Energy cost is estimated based on the weight, yield, pouring temperature and melting
equipment. Energy and tooling cost is the most difficult to estimate. The total cost is given as the sum of
costs corresponding to material, labour, energy, tooling and overhead costs.
Other costs related to interest rate, fixed cost, delivery, taxes; duties and premium can be added. These
elements are not considered in the present work, which focuses only on manufacturing cost driven by
product design. Also the energy cost, tooling cost and overhead cost cannot be analyzed in this project for
the design. For estimation of costs related to material, labour, and standard selected parts are presented in
the following subsections. The equations are generalized for any currency, that is, the cost values will be
obtained in the same currency.
8.2 Material cost
The material cost involves both direct and indirect materials. Direct materials appear in the final product
whereas indirect materials are essential for production but are not included in the final product. Moulding
sand, dispensable cores, insulating sleeves, chills etc. are indirect materials. The direct material cost can
be determined from the casting weight. However, the actual amount of metal consumed is more than the
weight of manufactured castings, owing to irrecoverable losses during melting, pouring and fettling. The
basic metal cost equation has been modified to incorporate these factors. Since rejected castings (defective
castings that cannot be repaired) are re-melted, the factor for rejection is not considered in direct material
cost equation.
Indirect materials depend on the process. The moulding sand and core sand constitute the main element of
indirect material cost. The cost of moulding sand depends on the type of sand (silica, olivine, zircon,
sodium silicate, etc.), composition (amount of binder), mould box size and layout. Core sand cost mainly
depends on the type of sand (represented by the core-making process) and volume of cores. Cost
modifiers for mould rejection, core rejection, casting rejection and sand reclamation have not considered
for this project.
From the appendix the total material cost is estimated as, the sum of the standard material and the direct
material cost which is 170,350.46 birr. (Appendix 19 and 20)
Page 83

8.3 Labour cost
The labour cost is a function of equipment, labour and time required for various activities in casting
production. This information is contained in the process plan. Some of the activities such as melting, sand
preparation and shakeout, are performed for a batch. The time per component for these activities has been
calculated based on casting weight, core weight, mould weight and number of castings, respectively. The
operational cost estimated from the appendix 18 is given as 8,462.1birr.
The total cost estimated based on the methodology of the cost estimation is 178,812.56birr.
Page 84
9. CONCLUSION AND RECCOMMENDATION

9.1 Conclusion
Crushers are major size reduction equipment used in mechanical, metallurgical and allied industries. They
are classified based on different factors like product size and mechanism used. Based on the mechanism
used crushers are of three types namely Cone crusher, Jaw crusher and Impact crusher.
Impact crushers are the latest breed of crushers in use. They have proved to be more efficient than the
other two major types of crushers and are rapidly replacing them. In the resent design we have tried to
concentrate on the design of major components of an Impact crusher and have been able to find
certain results.
The modern way of aggregate production requires aggregate crushing machines so that the quarry is
either drilled, blasted or dug with special mechanisms, fed to crushers, crushed, sieved and
separated according to their sizes.
The different sizes commonly known as 01, 02, 03 and 04 are
stockpiled separately. Size 02 means aggregates having a maximum aggregate size of 20mm,while 01, 03,
04 has a maximum aggregate size of 10, 30 and 40 mm respectively. This method enables to classify
aggregates based on their maximum aggregate sizes and enable engineers to suggest unique
mix proportion to arrive at the required concrete quality production.
9.2 Recommendation
The horizontal impact crusher is depending on the feed value. It is absolutely recommended to use the
same feed at the same speed in order to have a good working operation. The operator is not working the
own knowledge but depend on manual operation guideline time. Therefore the components are protected
from corrosion by the sacrificial lubrication and paint. It is advisable to check the life of the hammer and
rotor to change a new one. It is also recommended to make the horizontal impact crusher operational when
the day length is 8 hours. An extensive size reduction partition board from a significant number of
installations is used to crusher feed and size.
Generally, the project team will recommend that the design of the machine can be proceed with making it
the machine more attractive with user interference, adding automation system, designing input feeding
system also design conveyer system for the final product transportation.
Page 85
APPENDIX
Appendix 1: mass property
A) Mass properties of flywheel (Part Configuration solid work software)
Output coordinate System: -- default --Density = 0.00 grams per cubic millimeter
Mass = 21992.84 grams
Volume = 21992837.13 cubic millimeters
Surface area = 1199233.71 millimeters^2
Center of mass: (millimeters)
X = 0.00
Y = 0.02
Z = -0.00
Principal axes of inertia and principal moments of inertia: (grams * square millimeters)
Taken at the center of mass
Ix = (1.00, -0.00, 0.00)
Px = 1127587649.77
Iy = (0.00, 1.00, 0.00)
Py = 1127607855.83
Iz = (0.00, 0.00, 1.00)
Pz = 2232933573.24
Moments of inertia: (grams * square millimeters)

Taken at the center of mass and aligned with the output coordinate system.
Lxx = 1127587650.00
Lxy = -66.20
Lxz = 4.27
Lyx = -66.20
Lyy = 1127607855.61
Lyz = 10.24
Lzx = 4.27
Lzy = 10.24
Lzz = 2232933573.24

Taken at the output coordinate system
Ixx = 1127587658.69
Ixy = -66.17
Ixz = 4.27
Iyx = -66.17
Iyy = 1127607855.61
Iyz = 10.10
Izx = 4.27
Izy = 10.10
Izz = 2232933581.94
B) Mass properties of hammer (Part Configuration - solid work software)

Output coordinate System: -- default
Density = 0.01 grams per cubic millimeter
Page 86

X = -23.80
Y = -5.00
Z = 500.00
Ix = (0.00, 0.00, 1.00)
Px = 462561362.44
Iy = (1.00, 0.00, 0.00)
Py = 7211922562.53
Iz = (-0.00, 1.00, 0.00)
Pz = 7645909837.12

Lxx = 7211923583.50
Lxy = 665647.75
Lxz = -0.00
Lyx = 665647.75
Lyy = 7645908816.15
Lyz = 0.00
Lzx = -0.00
Lzy = 0.00
Lzz = 462561362.44

Ixx = 28806989429.96
Ixy = 10945210.86
Ixz = -1027956311.16
Iyx = 10945210.86
Iyy = 29287752469.65
Iyz = -215929065.56
Izx = -1027956311.16
Izy = -215929065.56
Izz = 513657750.79
C) Mass properties of new rotor plate (Part Configuration - solid work software)
X = 0.00
Y = 0.00
Z = 50.00
Page 87

Ix = (1.00, 0.00, 0.00)
Px = 881573870.97
Iy = (0.00, 1.00, 0.00)
Py = 881573870.97
Iz = (0.00, 0.00, 1.00)
Pz = 1634521414.20

Lxx = 881573870.97
Lxy = -0.00
Lxz = 0.00
Lyx = -0.00
Lyy = 881573870.97
Lyz = 0.00
Lzx = 0.00
Lzy = 0.00
Lzz = 1634521414.20

Ixx = 1074513362.58
Ixy = -0.00
Ixz = 0.00
Iyx = -0.00
Iyy = 1074513362.58
Iyz = 0.00
Izx = 0.00
Izy = 0.00
Izz = 1634521414.20
D) Mass properties of pulley ( Part Configuration - solid work software )

X = 55.32
Y = -109.07
Z = 0.00
Ix = (0.00, 0.00, 1.00)
Px = 11400951.94
Iy = (0.00, -1.00, 0.00)
Py = 11409612.99
Iz = (1.00, 0.00, 0.00)
Pz = 16771473.18

Page 88

Lxx = 16771473.18
Lxy = -17.09
Lxz = 0.00
Lyx = -17.09
Lyy = 11409612.99
Lyz = 0.00
Lzx = 0.00
Lzy = 0.00
Lzz = 11400951.94

Ixx = 49942026.07
Ixy = -16822773.62
Ixz = 0.00
Iyx = -16822773.62
Iyy = 19941431.51
Iyz = 0.00
Izx = 0.00Izy = 0.00
Izz = 53103323.34
E) Mass properties of small pulley (Part Configuration - solid work software )

Mass = 451.05 grams
X = 3.61
Y = 5.33
Z = 0.00
Ix = (1.00, 0.00, 0.00)
Px = 531409.69
Iy = (0.00, 0.00, -1.00)
Py = 940157.87
Iz = (0.00, 1.00, 0.00)
Pz = 940157.87

Lxx = 531409.69
Lxy = 0.00
Lxz = 0.00
Lyx = 0.00
Lyy = 940157.87
Lyz = 0.00
Lzx = 0.00
Lzy = 0.00
Lzz = 940157.87

Page 89

Ixx = 544238.04
Ixy = 8690.28
Ixz = 0.00
Iyx = 8690.28
Iyy = 946044.92
Iyz = 0.00
Izx = 0.00
Izy = 0.00
Izz = 958873.26
Appendix 2: mathematical simulation

A) Solid work software Study Results of rotor plate
Name
Type
Min
Location
Max
Location
Stress1
VON: von
7208.89
(-22.4895 mm,
1.63798e+007
(-55 mm,
Mises Stress
N/m^2
-198.73 mm,
N/m^2
0 mm,
Node: 237
100 mm)
Node: 13256
90 mm)
URES:
0 mm
(-55 mm,
0.0127651 mm
(198.732 mm,
Resultant
Node: 1
6.73556e-015
Node: 1031
22.5127 mm,
Displacement1
Displacement
mm,
60 mm)
100 mm)
Strain1
ESTRN:
3.74217e-008
(174.999 mm,
6.07112e-005
(-2.15725 mm,
Equivalent
Element: 77
-18.1198 mm,
Element: 1998
-56.1483 mm,
Strain
i)
30 mm)
92
Stress distribution
Page 90

ii)
Displacement distribution
iii)
Strain distribution
Page 91

iv)
Factor of Safety
v)
Design Insight
Page 92

B) solid work simulation of shaft design
i)
Stress distribution
ii)
Deflection distribution
Page 93

C) solid work software study results of size reducer shaft
Name
Type
Min
Location
Max
Stress1
VON: von
604668
(399.239 mm,
8.01772e+007 (15.2688 mm,
Mises Stress
N/m^2
Node: 11268
Displacement1 URES:
Resultant
Displacement
10.3931 mm,
6.81875 mm)
0 mm
(400 mm,
Node: 1636
-7.91939 mm,
-6.82418 mm)
Strain1
ESTRN:
Equivalent
Strain
i)
N/m^2
Node: 1689
0.0272776
mm
Node: 10534
Location
10.0035 mm,
-11.1824 mm)
(0.0271736 mm,
-0.00079368 mm,
-15.0022 mm)
6.22716e-006
(33.7012 mm,
0.000256104
(13.6813 mm,
Element:
-1.14505 mm,
Element:
10.4889 mm,
5508
3.0696 mm)
5387
-7.73255 mm)
Stress distribution
Page 94

ii)
iii)
Strain distribution
Page 95

D) solid work software study results the housing
Name
Type
Min
Stress1
VON: von
1921.4 N/m^2 (-246.337
Mises Stress
Node: 1900
Location
Max
Location
4.24257e+006 (584.163 mm,
mm,
N/m^2
356.929 mm,
Node: 22408
334.701 mm,
-413.156 mm)
360.955 mm)
Displacement1 URES:
Resultant
Displacement
0 mm
Node: 12
(-203.839
0.0113588
mm,
mm
-42.0716 mm,
Node: 22656
(177.716 mm,
362.924 mm,
-433.699 mm)
-360.688 mm)
Strain1
ESTRN:
Equivalent
Strain
9.81196e-009
Element:
2038
(-253.962
mm,
320.362 mm,
1.45651e-005
(575.162 mm,
Element:
331.897 mm,
11646
-400.531 mm)
224.312 mm)
i)
Stress distribution
Page 96

ii)
iii)
Strain distribution
Page 97

iv)
Design Insight
Appendix 2: Dimensions and load rating for single-row 02- series deep-groove and angle-contact
ball bearing [20]
Page 98

Appendix 3: Design dimensions of screw threads, bolts and nuts according to IS: 4218(partIII)
1979(reaffirmed 1996.[20]
Page 99

Appendix 4: Bearing house select
Page 100

Appendix 5: Fatigue strength of fraction f of Sut at 1000cyles. [20]
Appendix 6: Parameters for marine surface modification factor. [20]
Appendix 7: Round shaft with shoulder filler in torsion. [20],
, where
and
Page 101

Appendix 8: Round shaft with shoulder filler in torsion. [20],
, where
and
Appendix 9: Notch-sensitivity charts for steel and aluminum alloys subjected to reversed bending or
reversed axial loads. For larger notch radii, use the value of q corresponding to the t = 0.16in (4mm)
ordinate.[20]
Page 102

Appendix 10: Parameters in marin loading factor [20]
Appendix 11: Effect of operating temperature on the tensile strength of steel* (ST = tensile strength
at operating temperature; SRT = tensile strength at room temperature; 0.099 <
< 0.110) [20]
Appendix 12: Reliability factor [20]
Page 103

Appendix 13: Characteristics of spring material [17]
Appendix 14: Strength characteristics of building stress [4]
Page 104

Appendix 15: Total number of turns, old length and free length for defferent types end connection
and axially loaded helical spring [17]
Appendix 16: The values of coefficient of friction for various materials of belt and pulley [17]
Page 105

Appendix 17: Horse power of V belts [17]
Appendix 18: Direct labour cost

No.
Operation
Time (hr)
Rate (birr/hr)
Cost (birr)
Machining
24
57
1368
Forging
51
102
Pattern making
18
59.55
1071.9
Casting, Molding, melting, finishing.
12
47.01
564.12
Welding
72
65
4680
Heat treatment
56.28
337.68
Cold working
64.2
128.4
Assembly
35
210
Total
8462.1
Page 106

Appendix 19: Direct Standard part selected cost estimation
No.
Item
Weight(kg)
Speciation
Price/kg
Total price
Manganese
372.21
Molten
130
48,387.3
Plain carbon steel
385.88
molten
86
33,185.68
Gray cast iron
40
Molten
82
3280
Mild steel
170
Bar, dia 85mmx1500mm
54
9,180
AISI1020
5
AISI 9255
Bar, dia 35mmx500mm
63
126
AISI1018 low
249.479
Plate
120
29,937.48
carbon steel
12mmx2000mmthickness
Total
124,096.46
Appendix 20: Direct standard material cost

Part name
Quantity
Cost per item
Total cost
Bearing
1,500
3,000
Bearing house
1,500
3,000
Motor
16,000
26,000
Bolt (allen head)
56
38
2,128
Bolt (hexa head)
66
35
2,310
Washer
122
976
V- belt
3,000
3,000
Retaining ring
700
3,500
Key
780
2,340
Total
46,254
Page 107

Appendix 21: Cutting speed and feed operation [26]
Work
Tool
Cutting speed
material
material
Depth of cut in mm
5-10
2.5-5
0.5- 2.5
0.1- 0.5
0.5-0.6
0.3-0.5
0.25-0.35
0.05-0.25
20-50
50-70
40-50
50-120
100-150
125-175
150-250
200-500
25-35
35-50
40-60
45-80
60-120
85-150
120-200
150-450
15-25
25-45
25-50
35-70
30-65
60-120
100-150
120-300
15-20
15-25
15-36
120-300
30-65
40-80
65-100
80-180
15-20
20-25
25-30
30-60
35-60
60-120
100-150
120-300
15-20
20-25
20-30
25-50
35-60
40-70
50-80
50-90
Cast iron grey HSS carbide
20-25
25-30
30-45
40-60
ductile and
60-90
70-100
85-110
80-120
Feeds
Free
HSS carbide
machining
steels
Mild steel
Medium
HSS carbide
HSS carbide
carbon steels
Alloy steel
Tool steel
Stainless steel
HSS carbide
HSS carbide
HSS carbide
malleable
Page 108

Appendix 22: Speeds generally used for drilling [26]
Work material
Cutting speed(m/min)
Drilling
Free machining steels
20 30
Mild steel
20 25
Medium carbon steel
15 20
Alloy steel
15 22
Tool steel
58
Stainless steel
10 15
Cast iron
20 25
Appendix 23: Dimension of standard V belt. [17]
Appendix 24: Dimension of standard V grooved pulleys. [17]
Page 109

Appendix 25: Part drawing
Page 110
Page 111
Page 112
Page 113
Page 114
Page 115
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Design of Impact Stone Crushing Machine

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Design of Impact Stone Crushing Machine

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ADAMA SCIENCE AND TECHNOLOGY UNIVERSITY

School of Mechanical Chemical and Material Engineering

Department of Mechanical and vehicle engineering

Design of impact stone crusher machine

ADAMA SCIENCE AND TECHNOLOGY UNIVERSITY

Design of impact stone crusher machine

Project submitted in partial fulfillment of the

Advisor: Getaw Ayay (M.Sc.)

Design of impact stone crusher machine, 2015

ADAMA SCINCE AND TECHINOLOGY UNIVERSITY

Design of impact stone crusher machine, 2015

forces. Based on the mechanism used crushers are

Design of impact stone crusher machine, 2015

Design of impact stone crusher machine, 2015

Design of impact stone crusher machine, 2015

Design of impact stone crusher machine, 2015

Design of impact stone crusher machine, 2015

P = Equivalent static force

Design of impact stone crusher machine, 2015

Design of impact stone crusher machine, 2015

Maximum principal tensile stress

Design of impact stone crusher machine, 2015

Design of impact stone crusher machine, 2015

Figure 1.1: A man crushing stone traditionally

Design of impact stone crusher machine, 2015

Design of impact stone crusher machine, 2015

Design of impact stone crusher machine, 2015

Design of impact stone crusher machine, 2015

Design of impact stone crusher machine, 2015

Design of impact stone crusher machine, 2015

Less capital outlay.

High degree of product size control

Long life of wear components.

Large feed port, deep crushing chamber, high reduction ratio(20:1)

Manganese steel flat hammer wear resistance, great impact force

Easy operation and maintenance

Design of impact stone crusher machine, 2015

Design of impact stone crusher machine, 2015

happened because of rainfall during the eruption. Scoria aggregate is found

Design of impact stone crusher machine, 2015

Figure 2.1: Rotor assembly and housing/ casing of concept one

Figure 2.2: Rotor assembly and casing of concept two

Design of impact stone crusher machine, 2015

Figure 2.3: Rotor assembly and overall assembly of concept three

Design of impact stone crusher machine, 2015

Design of impact stone crusher machine, 2015

Design of impact stone crusher machine, 2015

Design of impact stone crusher machine, 2015

Initial kinetic energy of the system before impact is

Final kinetic energy of the system is,

Design of impact stone crusher machine, 2015

The initial velocity of the particle would be found from

Tonnage per impact is given by

The initial velocity of the particle would be found from

Design of impact stone crusher machine, 2015

Crack propagation velocity is given by

The dynamic stress will be given as

Torque required will be given by

Design of impact stone crusher machine, 2015

5. MATERIAL SELECTION AND DETAIL DESIGN

Design of impact stone crusher machine, 2015

By combining the deflection and strain energy equation:

Data for design: