DESIGN & FABRICATION OF WASTAGE MATERIALS

SEPARATING MACHINE

A PROJECT REPORT

Submitted by

K.MOULI (421116114043)
K.KALAI SELVAN (421116114035)

In partial fulfillment for the award of the degree

of
BACHELOR OF ENGINEERING
in
MECHANICAL ENGINEERING

I.F.E.T COLLEGE OF ENGINEERING

VILLUPURAM – 605 108
ANNA UNIVERSITY: CHENNAI 600 025
APRIL 2019

ANNA UNIVERSITY: CHENNAI 600 025

 BONAFIDE CERTIFICATE

Certified that the project report “DESIGN AND FABRICATION OF WASTAGE

MATERIALS SEPARATING MACHINE” is the bonafide work of “K.MOULI
(421116114043), K.KALAISELVAN (421116114035)” who carried out the project
work under my supervision.

SIGNATURE SIGNATURE

Mr.V.VELMURUGAN, Miss.NARMADHA DEVI ,

HEAD OF THE DEPARTMENT, SUPERVISOR,

Mechanical Engineering, Mechanical Engineering,

I.F.E.T College of Engineering, I.F.E.T College of engineering,

Villupuram – 605 108. Villupuram – 605 108.

Submitted for the Anna University Examination held on ………………..

INTERNAL EXAMINER EXTERNAL EXAMINER

ACKNOWLEDGEMENT
 It gives us immense pleasure to express our sense of gratitude to those who
helped us in bringing out the project work successfully. We take this opportunity to
record our thanks to our management, IFET College of Engineering for providing
all the facilities to complete our project work successfully.

We express our deep sense of gratitude to our beloved Principal

Dr.G.MAHENDRAN, M.Tech. (IITM), Ph.D., for his constant encouragement
throughout our course of study and providing all facilities.

We are extremely grateful to our Vice principal, Dr.S.MATILDA, M.S.,

Ph.D., and Dean Placement Prof.J.ASHA, M.E., (Ph.D)., for their incitement and
created enthusiasm to make our project work wonderful and successful one.

We are extremely thankful to our respected Head of the Department,

Mr.V.VELMURUGAN, M.Tech., (Ph.D)., for approving our project work with
great interest.

We would like to articulate our profound gratitude to our internal guide,

Miss.NARMADHA DEVI ., Senior Assistant Professor, who tirelessly helped and
encouraged us during the course of this project. It has been a great pleasure for us
to get an opportunity to work under him and complete the project successfully.

Our sincere thanks to our Faculty Advisor and our Project Coordinator
Mr.K.MADESHWARAN, M.E., Senior Assistant Professor, for his incitement
and passion to make our project a successful one and also extend our thanks to all
the faculty and non-teaching faculty of our department.

Last but not least, our sincere thanks to our lovely parents and friends who
has been the constant source of our strength throughout our life.

K.MOULI

K.KALAI SELVAN

TABLE OF CONTENTS
CHAPTER NO. TITLES PAGE NO.

LIST OF TABLES vi

LIST OF FIGURES vii

ABSTRACT viii

1 INTRODUCTION 1

2 LITERATURE SURVEY 3

3 COMPONENTS USED 5
3.1 ROD 5
3.2 SPUR GEARS 6
3.3 LUG NUT REMOVER 7
3.4 BALL BEARING 8

3.5 9

3.12 GI SHEETS 17
3.13 AIR SYSTEMS 18
3.13.1 BLOWER 18

4 MECHANISMS USED 19
 4.1 ECCENTRIC MECHANISM 19
4.2 BEVEL GEAR 20
4.3 CONVEYER BELT SETUP 20

5 MANUFACTURING PROCESS 21
5.1 CUTTING 21
5.2 WELDING 22
5.3 DRILLING 23

6 WORKING PRINCIPLE 24
6.1 SAND FILERING ZONE 24
6.2 PLASTICS & PAPERS FILTERING ZONE 25
6.3 METAL SEPARATING ZONE 25
6.4 NON-METAL SEPARATING ZONE 25
v

7 EXPERIMENTAL RESULTS 26

8 DESIGN DIAGRAM 27

9 ADVANTAGES 28

10 COST ESTIMATION 29

11 CONCLUSION 30
 12 FUTURE SCOPE 30

13 REFERENCE 31

LIST OF TABLES

TABLE.NO NAMES PAGE.NO

7.1 EXPERIMENTAL RESULTS 26

10.1 COST ESTIMATION 29

vi
 LIST OF FIGURES

FIGURE.NO NAMES PAGE.NO

3.1 SQUARE PIPE 5

3.2 BELT DRIVES 6
3.3 WOODEN ROLLERS 7
3.4 BALL BEARING 8
3.5 FIBER POROUS BED 9
3.6 0.25 HP MOTOR 10
3.7 DC MOTOR (WIPER MOTOR) 11
3.8 RECTIFIER 12
3.9 BEVEL GEAR SETUP 13
3.10 NEUTRAL COIL ROTATING MAGNET 15
3.11 ACP SHEET 16
3.12 GI SHEETS 17
3.13 BLOWER 18
5.1 CUTTING 21

5.2 WELDING 22

5.3 DRILLING 23

8.1 DESIGN DIAGRAM 27

vii

1
 ABSTRACT

It is very

NAME OF THE TYPE OF QUANTITY COST OF

MATERIAL MATERIAL MATERIAL
1.Box Spanners CAST IRON 4 500/-
2.Sun Gear MILD STEEL 4 350/-
3.Shaf MILD STEEL 5 200/-
4.Bush STEEL 60/-
5.Steel Plate MILD STEEL 1 350/-
6.Planet Gear M.S 1 500/-
7.TOTAL COST

2
 CHAPTER 1

INTRODUCTION

Solid waste is generated from industrial, residential and commercial

activities in a given area, and may be handled in a variety of ways. As such,
landfills are typically classified as sanitary, municipal, construction and
demolition or industrial waste sites. Waste can be categorized based on
materials such as plastic, paper, glass, metal, and organic waste.

Categorization may also be based on hazard potential including

radioactive, flammable, infectious, toxic and non-toxic. Categories may also
pertain to the origin of waste such as industrial, domestic, commercial,
institutional or construction and demolition.

Regardless of the origin, content or hazard potential, solid waste must be

managed systematically to ensure environmental best practices. As solid waste
management is a critical aspect of environmental hygiene, it needs to be
incorporated into environmental planning. Inorganic waste is waste consisting
of materials that are difficult biodegradable so that destruction takes a very long
time.

Inorganic rubbish comes from non renewable natural resources such as

minerals and petroleum, or from industrial processes. Some of this material was
not found in nature such as plastic and aluminum. Some inorganic substances as
a whole cannot be explained by nature, while others can only be described in a
very long time. This types of waste at the household level, for example in the
form of bottles, plastic bottles, plastic bags, and cans.

1
 Examples of waste from inorganic waste are: pieces / plates of metal,
various kinds of stones, glass shards, bones, tin cans, bottles, paper, and others.
This type of waste, it is good to see the physical hardware for low-elevation soil
or can be to widen the path. But if diligently working on waste from metal can
be re-melted for useful items, rocks to low soil amplifying paths, broken glass
can be melted down and re-used items handy, and when crushed bones can
fatherly fertilizers and others.

With the decline in the quality and aesthetics of the environment,

resulting in visitors or tourists are reluctant to visit the tourist area because it
was uncomfortable, and the tourist areas are less attractive to visit. As a result,
the number of tourist arrivals decreased, which means that foreign countries
also declined. Inorganic waste cannot be degraded naturally. With creativity,
this waste can be recycled for a variety of needs.

There is some waste that can be used: Waste paper can be gathered into
one part that is separated from other waste. Whether further trashed or sold to
the junkman, at least we have the waste management easy steps to perform
advanced processing. Collection of waste paper can be made many different
types of crafts, such as masks, statues, and recycled paper. Sale value of waste
paper recycling is much higher than normal paper waste.

Garbage cans can be used for items of daily necessities. While mineral
resources cannot be updated, if it can even take hundreds or even thousands of
years to shape it. One day it will run out of minerals explored. Therefore, it
would be wise if we took part in the success of the recycling movement. 100%
steel cans can be recycled due to its longer life cycle.

2
 CHAPTER 2

LITERATURE SURVEY

This project is to design and fabricate a waste material separating

machine to separate the inorganic wastages according to their material
properties. The rotating disc of neutral coil for metal separation is complicated
and new method.

All the previous methods have many disadvantages which are rectified
by this method. Some of the previous methods used for waste separation
process are landfill, incineration and chemical process which produces harmful
to the environment and causes degradation. To rectify this, simple mechanical
components are used for separating the wastages.

In June 2013, Automatic Plastic Separating Technology for Solid Waste

Disposal is done by Joice Jonny has certain disadvantages in separating the
plastics. Due to heating the plastics the slurry is formed at the outlet of the
plastic separator. It will be in a mixed form and the total Cost of the project is
very high when compared to this project

In March 1993, Apparatus and method for separation, recovery, and

recycling Municipal Solid Waste and the like is done by Clifford C. Holloway.
This machine handling is tedious process and high maintenance is required for
the machine during work. These demerits are overcome by this separating
machine which has less maintenance and easy handling of materials.

In Solid waste management, there are three types of disposal methods.

They are landfill, incineration and composting. In Landfill method, solid wastes

3
are placed in sanitary landfill system in alternate layers of 80 cm thick refuse,
covered with selected earth fill of 20 cm thickness. After 2-3 years, solid waste
volume shrinks by 25-30% and the land is used for roads.

But it requires a large area. Bad odors will be created, if landfills are
not properly managed. The land filled areas will be the sources of the
mosquitoes and flies and hence insecticides and pesticides are to be applied at
regular intervals. These problems have been overcome by this wastage
separating machine.

It will produce ashes by means of burning and the flame causes severe
air pollution to the environment. The capital cost is high. It needs a skilled
person. These problems have been overcome by this wastage separating
machine.

4
 CHAPTER 3

COMPONENTS USED

There are many mechanical and electrical components are used in this
machine. They are explained as follows:

3.1 Square Pipe

A hollow structural section (HSS) is a type of metal profile with a

hollow square cross section. It acts as a supporting member for heavy loads. In
this project heavy weight square pipes are used for withstanding heavy load.

HSS members can be circular, square, or rectangular sections, although

other shapes such as elliptical are also available. HSS is only composed
of structural steel per code.

HSS is sometimes referenced as hollow structural steel. Rectangular

and square HSS are also commonly called tube steel or structural tubing.
Circular HSS are sometimes called as steel pipe, although true steel pipe is
actually dimensioned and classed differently from HSS.

Fig. 3.1 Square Pipe

5
3.2 Belt drives

A belt is a flexible material used to link two or more rotating shafts

mechanically, most often parallel. Belts may be used as a source of motion,
to transmit power efficiently or to track relative movement. Belts are looped
over pulleys and may have a twist between the pulleys, and the shafts need not
be parallel.

In a two pulley system, the belt can either drive the pulleys normally in
one direction (the same if on parallel shafts), or the belt may be crossed, so that
the direction of the driven shaft is reversed (the opposite direction to the driver
if on parallel shafts). As a source of motion, a conveyor belt is one application
where the belt is adapted to carry a load continuously between two points.

Belts are the cheapest utility for power transmission between shafts that
may not be axially aligned. Power transmission is achieved by specially
designed belts and pulleys. The demands on a belt-drive transmission system
are huge, and this has led to many variations on the theme. They run smoothly
and with little noise, and cushion motor and bearings against load changes,
albeit with less strength than gears or chains.

Fig. 3.2 Belt Drive

6
3.3 Wooden rollers

A roller is a wheel on an axle or shaft that is designed to support

movement and change of direction of a taut cable or belt, or transfer of power
between the shaft and cable or belt.

In the case of a pulley supported by a frame or shell that does not

transfer power to a shaft, but is used to guide the cable or exert a force, the
supporting shell is called a block, and the roller may be called a sheave.

A roller may have a groove or grooves between flanges around

its circumference to locate the cable or belt. The drive element of a lexar system
can be a rope, cable, belt, or chain.

Powered roller belts are also called motorized roller belts, RollerDrive
belts, Power Moller belts, and Microroller belts. They connect a motorized
roller to a group of six to ten slave rollers, called a zone. Usually the motorized
roller is in the center of the zone, but on inclines it is at the top end.

Rollers are assembled to form a block and tackle in order to

provide mechanical advantage to apply large forces. Rollers and Pulleys are
also assembled as part of belt and chain drives in order to transmit power from
one rotating shaft to another.

Fig. 3.3 Wooden rollers

7
3.4 Ball Bearing

A ball bearing is a type of rolling-element bearing that uses balls to

maintain the separation between the bearing races. The purpose of a ball
bearing is to reduce rotational friction and support radial and axial loads.

It achieves this by using at least three races to contain the balls and
transmit the loads through the balls. In most applications, one race is stationary
and the other is attached to the rotating assembly (e.g., a hub or shaft).

As one of the bearing races rotates it causes the balls to rotate as well.
Because the balls are rolling they have a much lower coefficient of friction than
if two flat surfaces were sliding against each other.

Ceramics such as silicon nitride are now regularly used in such

applications due to their low density (40% of steel). These materials
significantly reduce centrifugal force and function well in high temperature
environments.

Ball bearings tend to have lower load capacity for their size than other
kinds of rolling-element bearings due to the smaller contact area between the
balls and races.

Fig. 3.4 Ball Bearing

8
3.5 Fiber Porous Bed

Fiber porous bed is a type of porous bed used to filter the sand particles for
the maximum size of 8 mm of hole. It consist matrices of pores for sand filtering. A
sand bed filter is a kind of depth filter. Sand bed filters work by providing the
particulate solids with many opportunities to be captured on the surface of a sand
grain. As sand particles flows through the porous bed along a tortuous route, the
particulates come close to sand grains.

The pressure drop across a clean sand bed is usually very low. It builds as
particulate solids are captured on the bed. Particulate solids are not captured
uniformly with depth, more are captured higher up with bed with the concentration
gradient with the application of vibrations. The material for the porous bed is a
fiber because it has a good corrosion resistance to other materials and has high
strength ratio. Fiber porous bed produces very less noise during the vibrations
when compared to the metal porous beds.

Fig.3.5 Fiber Porous Bed

9
3.6 0.25 HP Motor

An electrical machine that converts electrical energy into a mechanical

energy is a motor. The reverse of this is the conversion of mechanical energy
into electrical energy and is done by an electric generator, which has much in
common with a motor. It consists of 0.25 Horse Power motor for providing
vibrations on the surface of the porous bed. A linkage is connected between the
motor shaft and the porous bed for transmitting the vibrations with the
frequency of 50 Hz.

Most electric motors operate through the interaction between an electric

motor's magnetic field and winding currents to generate force. In certain
applications, such as in regenerative braking with traction motors in the
transportation industry, electric motors can also be used in reverse as generators
to convert mechanical energy into electric power.

When a minimum load is applied to the series, the motor rotates with
the low speed. When the maximum load is applied to the series, the motor
rotates with high speed. The motor creates a parallel effect on the series circuit.

Fig.3.6 0.25 HP Motor

10
3.7 DC Motor (Wiper Motor)

A DC motor is a class of rotary electrical machines that converts

direct current electrical energy into mechanical energy. Nearly all types of DC
motors have some internal mechanism, either electromechanical or electronic,
to periodically change the direction of current flow in part of the motor. The
most common types rely on the forces produced by magnetic fields. It is the
separately excited DC motor that develops highest torque at low speed. The
major specifications of wiper motor are: Motor Torque Range: 13 to 120 N m,
overload protection, Greater life cycle and corrosion resistance.

The speed range of the DC Wiper motor is from 45 rpm to 65 rpm. It

produces very less noise during operations and withstand varying load capacity
of the motor. It is coupled with the belt drive to operate the wastage materials
from one zone to another zone. The efficiency of the DC motor will be high
when compared to other AC and DC motors due to the continuous current flow
on the windings of the motor.

Fig.3.7 DC Motor (Wiper Motor)

11
 3.8 Rectifier

A rectifier is an electrical device that converts alternating current (AC),

which periodically reverses direction, to direct current (DC), which flows in
only one direction. The process is known as rectification, since it "straightens"
the direction of current.

Physically, rectifiers take a number of forms including vacuum tube

diodes, mercury-arc valves, stacks of copper and selenium oxide
plates, semiconductor diodes, silicon-controlled rectifiers and other silicon-
based semiconductor switches.

Historically, even synchronous electromechanical switches and motors

have been used. Rectifiers have many uses, but are often found serving as
components of DC power supplies and high-voltage direct current power
transmission systems.

Rectification may serve in roles other than to generate direct current

for use as a source of power. As noted, detectors of radio-signals serve as
rectifiers. In gas heating systems flame rectification is used to detect presence
of a flame.

12
 Fig.3.9 Rectifier

3.9 Bevel Gears Setup

Bevel gears are gears where the axes of the two shafts intersect and
the tooth-bearing faces of the gears themselves are conically shaped. In this
wastage separating machine process, bevel gears are used to connect the parallel
and perpendicular shafts. Bevel gears are most often mounted on shafts that are
90 degrees apart, but can be designed to work at other angles as well.

The pitch surface of bevel gears is a cone. Straight bevel gears are the
most common and also the simplest type of bevel gear. True to their name,
straight bevel gears have straight teeth and resemble a spur gear, except that they
are conical rather than cylindrical.

They also share many properties of spur gears due to the similar tooth
shape and the way their teeth engage. Bevel gears are known for their
consistency, precision, and dependability. We can manufacture straight bevel
gears up to 36” in diameter, and we work with a variety of materials, allowing us
the capability to meet the most demanding application requirements.

13
 Fig.3.10 Bevel Gear Setup

3.10 Magnetic system

A magnetic system is made up of one or more closed loop paths

containing a magnetic flux. The flux is usually generated by permanent
magnets or electromagnets and confined to the path by magnetic
cores consisting of ferromagnetic materials like iron, although there may be air
gaps or other materials in the path. Magnetic circuits are employed to efficiently
channel magnetic fields in many devices such as electric
motors, generators, transformers, relays,lifting electromagnets, SQUIDs, galvan
ometers, and magnetic recording heads.

A magnetic field is a force field that is created by moving electric

charges (electric currents) and magnetic dipoles, and exerts a force on other
nearby moving charges and magnetic dipoles. At any given point, it has
a direction and a magnitude (or strength), so it is represented by a vector field.

Magnetic fields are produced by moving electric charges and the

intrinsic magnetic moments of elementary particles associated with a
fundamental quantum property and their spin.

14
3.10.1Types of Magnets
3.10.1.1 Permanent Magnet

A permanent magnet is an object made from a material that

is magnetized and creates its own persistent magnetic field. An everyday
example is a refrigerator magnet used to hold notes on a refrigerator door.
Materials that can be magnetized, which are also the ones that are strongly
attracted to a magnet, are called ferromagnetic or ferrimagnetic. These
include iron, nickel, cobalt, some alloys of rare-earth metals, and some naturally
occurring minerals such as lodestone.

3.10.1.2 Temporary Magnet

3.10.1.2.1 Neutral Coil Magnetic Disc

It is a new type of rotating disc consists of two neutral coils

perpendicular to each other in the disc. A metal piece is connected with the
neutral coil individually. One end of the neutral coil is connected with the phase
of the electricity and the other end is connected with the earth of it. The neutral
coil rotating disc is rotated by means of bevel gears and gears are powered by
the DC motor. When the power supply is switched on the hinged needle touches
the upper contact plate of the neutral coil to transfer the electrical supply to
them. Therefore the metal piece magnetizes. When the power is switched off,
the metal piece will get demagnetized.

15
 Fig.3.10 Neutral Coil Magnetic Disc

3.11 ACP Sheet

Aluminium composite panels (ACP), made of aluminium composite

material(ACM), are flat panels consisting of two thin coil-
coated aluminium sheets bonded to a non-aluminium core. ACP Sheets are used
as a support for handling the additional weight of the wastage mixtures. It
separated the contact between the bevel gears and the canvas belt drive. ACP
has been used as a light-weight but very sturdy material in construction,

ACP are frequently used for external cladding or facades of buildings,

insulation, and signage. ACP is mainly used for external and internal
architectural cladding or partitions, false ceilings, signage, machine coverings,
container construction, etc.

Applications of ACP are not limited to external building cladding, but

can also be used in any form of cladding such as partitions, false ceilings, etc.

16
ACP is also widely used within the signage industry as an alternative to heavier,
more expensive substrates.

Fig.3.11 ACP Sheet

3.12 GI Sheets

Galvanization or galvanizing is the process of applying a

protective zinc coating to steel or iron to prevent rusting. It is applied as an
outer shield for the wastage separating machine for preventing the external
environmental factors. The most common method is hot-dip galvanizing, in
which parts are submerged in a bath of molten zinc. The zinc coating, when
intact, prevents corrosive substances from reaching the underlying steel or
iron. They are more flexible in nature when required forces are applied on the
materials. Although galvanizing will inhibit attack of the underlying steel,
rusting will be inevitable after some decades of exposure to weather, especially
if exposed to acidic conditions. For example, corrugated iron sheet roofing will

17
start to degrade within a few years despite the protective action of the zinc
coating. Galvanized car frames exemplify this; they corrode much faster in
cold environments due to road salt, though they will last longer than
unprotected steel. They are paint coated.

Fig.3.12 GI Sheet

3.13 Air Systems

An Air system is a additional system for increased velocity of air

greater than the atmospheric air. Pneumatic systems, blowers of different ranges
of speeds are used in different fields. Pneumatic systems used in industry are
commonly powered by compressed air or compressed inert gases. A centrally
located and electrically powered compressor powers cylinders, air motors, and
other pneumatic devices.

3.13.1 Blower

18
 Blowers are mechanical devices used for circulation of air. Based on
this, they are differentiated from each other, wherein a fan circulates air around
an entire room, or space, and a blower only focuses on the specific or given
area. Generally, a blower is a mechanical device that consists of a fan, and
which channels the air from the fan and directs it to a specific location or point.
Also, a fan circulates the air around an entire room or a large area, while a
blower is only positioned to a specific direction or point. It is used for blowing
out the particles of less molecular weight with high speed.

Fig.3.13 Blower

CHAPTER 4

MECHANISMS USED

There are three mechanisms used in the wastage material separating

machine. They are as follows,

4.1 Eccentric Linkage Mechanism for Vibration

19
 In mechanical engineering, an eccentric is a circular disk
(eccentric sheave) solidly fixed to a rotating axle with its centre offset from
that of the axle (hence the word "eccentric", out of the centre).

It is used most often in steam engines, and used to convert rotary into
linear reciprocating motion to drive a sliding valve or pump ram. To do so, an
eccentric usually has a groove at its circumference closely fitted a circular
collar (eccentric strap). An attached eccentric rod is suspended in such a way
that its other end can impart the required reciprocating motion.

A return crank fulfills the same function except that it can only work at
the end of an axle or on the outside of a wheel whereas an eccentric can also be
fitted to the body of the axle between the wheels.

Unlike a cam, which also converts rotary into linear motion at almost
any rate of acceleration and deceleration, an eccentric or return crank can only
impart simple harmonic motion.

The Eccentricity in the motor shaft coupled produces high vibrations at

very high speeds. These vibrations are in the form of vertical directions.

4.2 Bevel Gears for perpendicular & intersecting shafts in rotating disc

Bevel gears are gears where the axes of the two shafts intersect
and the tooth-bearing faces of the gears themselves are conically shaped.
Bevel gears are most often mounted on shafts that are 90 degrees apart,
but can be designed to work at other angles as well. The pitch surface of
bevel gears is a cone.

20
 The most familiar kinds of bevel gears have pitch angles of less
than 90 degrees and therefore are cone-shaped. This type of bevel gear is
called external because the gear teeth point outward. The pitch surfaces of
meshed external bevel gears are coaxial with the gear shafts; the apexes of
the two surfaces are at the point of intersection of the shaft axes.

4.3 Conveyor Belt Drive for Transporting Wastages

A conveyor belt is the carrying medium of a belt conveyor

system. A belt conveyor system consists of two or
more pulleys sometimes referred to as drums, with an endless loop of
carrying medium the conveyor belt that rotates about them. One or both of
the pulleys are powered, moving the belt and the material on the belt
forward.

The powered pulley is called the drive pulley while the

unpowered pulley is called the idler pulley. There are two main industrial
classes of belt conveyors. Those in general material handling such as
those moving boxes along inside a factory, transporting wastages and bulk
material handling such as those used to transport large volumes of
resources and agricultural materials, such
as grain, salt, coal, ore, sand, overburden and more.

CHAPTER 5

MANUFACTURING PROCESS

21
 5.1 CUTTING

Cutting is the separation of a physical object, into two or more

portions, through the application of an acutely directed force. Implements
commonly used for cutting are the knife and saw, or in medicine and science
the scalpel and microtome. However, any sufficiently sharp object is capable of
cutting if it has a hardness sufficiently larger than the object being cut, and if it
is applied with sufficient force. Even liquids can be used to cut things when
applied with sufficient force

Cutting is a compressive and shearing phenomenon, and occurs

only when the total stress generated by the cutting implement exceeds the
ultimate strength of the material of the object being cut. The stress generated by
a cutting implement is directly proportional to the force with which it is applied,
and inversely proportional to the area of contact.

Fig.5.1 Cutting Machine

5.2 WELDING

Welding is a fabrication or sculptural process that joins materials,

usually metals or thermoplastics, by causing fusion, which is distinct from

22
lower temperature metal-joining techniques such as brazing and soldering,
which do not melt the base metal.

In addition to melting the base metal, a filler material is typically

added to the joint to form a pool of molten material that cools to form a joint
that is usually stronger than the base material. Pressure may also be used in
conjunction with heat, or by itself, to produce a weld. Welding also requires a
form of shield to protect the filler metals or melted metals from being
contaminated or oxidized.

Arc welding is a process that is used to join metal to metal by using

electricity to create enough heat to melt metal, and the melted metals when
cool result in a binding of the metals. It is a type of welding that uses a welding
power supply to create an electric arc between an electrode and the base
material to melt the metals at the welding point.

Fig.5.2 Welding

5.3 DRILLING

23
 Drilling is a cutting process that uses a drill bit to cut a hole of
circular cross-section in solid materials. The drill bit is usually a rotary cutting
tool, often multi-point. The bit is pressed against the work-piece and rotated at
rates from hundreds to thousands of revolutions per minute. This forces the
cutting edge against the work-piece, cutting off chips (swarf) from the hole as
it is drilled.

In rock drilling, the hole is usually not made through a circular

cutting motion, though the bit is usually rotated. Instead, the hole is usually
made by hammering a drill bit into the hole with quickly repeated short
movements. The hammering action can be performed from outside the hole
(top-hammer drill) or within the hole (down-the-hole drill, DTH). Drills used
for horizontal drilling are called drifter drills. In rare cases, specially-shaped
bits are used to cut holes of non-circular cross-section; a square cross-section is
possible. Drilled holes are characterized by their sharp edge on the entrance
side and the presence of burrs on the exit side (unless they have been
removed). Also, the inside of the hole usually has helical feed marks.

Fig.5.3 Drilling

CHAPTER 6

24
 WORKING PRINCIPLE

In this wastage materials separating machine, there are three

zones for separating the wastage materials according to their
material properties. They are: Sand filtering Zone, Papers and
Plastics Filtering Zone, Metal separating Zone and Non-metal
Filtering zone

6.1 SAND FILTERING ZONE

A 0.45 kg of Wastage materials of inorganic substances in a mixed

content are taken as an input.

An eccentric linkage mechanism is fixed between the Motor shaft and

the Fiber Porous Bed in order to generate vibrations with greater amplitude.
The shaft is driven by 0.25 HP Motor.

The sand particles present in the Wastage mixtures are filtered out
separately at the bottom surface of the machine due to the dynamic effect of
vibration of fiber porous bed.

The maximum size of particles in sand that are filtered is 8 mm

diameter. Therefore sands particles are separated.

6.2 PLASTICS & PAPER FILTERING ZONE

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 Plastics and papers used commercially are of very less weight except
a few. In general, the molecular weight of the paper and the plastics are very
less. Therefore the velocity of air due to blower force the less weight molecule
materials are separated.

6.3 METAL SEPARATING ZONE

Mostly the metals are having the same property to attract with the
magnetic field.

A Neutral Coil rotating Disc is placed at the third zone and rotates
with speed greater than the conveyor belt speed.

Due to the power supply the neutral coil generates a magnetic field
and magnetizes the metal.

6.4 NON-METAL FILTERING ZONE

During the last stage, the wastage particles consists of e-wastes,

Non-metals like glass, ceramics, wood, composites and rubber are

present.

These materials are separated into a collecting box.

CHAPTER 7

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 EXPERIMENTAL RESULTS

Calculations are made after the working of waste material separating machine.
The timings of wastage separation are given as follows.

MASS (kg)

0.50 kg

14 1500 20% Non-metals

CHAPTER 8

DESIGN DIAGRAM

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 Fig.8.1

All dimensions are in mm

1. Plastics & papers collecting box. 2. Metal piece (CI) 3. Neutral Coil
4. Rotating disc. 5. Porous Bed. 6. Blower. 7. 0.25 HP Motor for vibration.
8. 1 inch Square Pipe. 9. Rollers. 10. Canvas Belt 11. Slow speed Motor.
12. Non-metals collecting boxes.

CHAPTER 9

ADVANTAGES

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 1. Separation of the given inorganic wastages materials from waste stream
for reuse, recycling or processing which is suitable for use as a raw material for
manufacturing.

2. It totally reduces the environmental pollutions.

3. It is a less time consuming process.

4. This reduces the wastage area occupied in the road side and provides
clean environment.

5. Metals with magnetic property can be easily separated.

6. Easy operation.

7. Machine can be handled by a single person.

8. Portable.(i.e., used as an automobile for collecting waste from different

areas).

9. Eco-friendly.

10. It does not have any chemical processes.

CHAPTER 10

COST ESTIMATION

29
S.No ITEMS QUANTITY PRICE
( Rs)

1 SQUARE CHANNEL 2 600

2 BEARING 3 250
3 WOODEN ROLLERS 2 300
4 FIBROUS PLATE BED 1 150
5 DC Motor 1 600
6 Rectifier 1 500
7 0.25 HP Motors 1 400
8 Neutral Coil set up 1 650

9 GI Sheets 1 300
10 Bevel Gear setup 1 600
11 Others 2160
TOTAL 6510

Table. 10.1

CHAPTER 11

CONCLUSION

By implementing this wastage separating machine we can easily

control the pollutions created by inorganic substances because they are non
biodegradable in nature and it causes soil pollution etc. Mostly the separated
wastages are easily recycled to the respective industries and reduce the source
of demand. It reduces the degradation of natural resources. Therefore the
wastage separating machine provides a better and clean environment. It can be
implemented in industries such as small scale and large scale industries.

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 CHAPTER 12

FUTURE SCOPE

The scope for this project is that is simple in construction, design and
low price when compared to the previous methods. Mostly 3/5th of the Inorganic
wastages are separated. This method can be used in static and dynamic
conditions with maximum efficiency. Further improvement in the design of
machine to separate the e-waste and non-metals will have a greater scope in
future. By using sensors in the waste separating machine, the accuracy and
effectiveness of the machine will be increased.

CHAPTER 13
REFERENCES

1. “Automatic Plastic Separating Technology for Solid Waste Disposal”,

Joice Johny, Della Sunny, Shaji M Jamal, June 2013.

2. “Process for Disaggregating waste materials which contain at least

partially reusable elements”, Heinz Hoberg, Joachim Christiani, Michael
Langen; Martin Bender, April 2001.

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 3. “Municipal Solid Waste Material Sorting Trommel System”, Harold B.
Mackenzie, April 1991.

4. “Waste Separating, Processing and Recycling System”, John A. Boyd,

June 1991.

5. “Apparatus and method for separation, recovery, and recycling

Municipal Solid Waste and the like”, Clifford C. Holloway, March 1993

32